I'm designing a breech for an assault weapon, and I am searching for a manufacturing process combining cheap costs of high production with precision and accuracy; I was considering die casting the parts, because I have read that this process is one of the most precise casting methods, and I believe casting is cheaper than milling (correct me if i'm wrong?)
Die casting might be the way to go if you can design your part geometry to be suitable for the process. For your info, I have recently obtained quotation comparisons between CNC machining from solid and Al die casting+some post-machining. They showed a 60% cost saving in the case of the component I was looking at. It might be worth you doing the same - put out 2 drawings out for quotation and see the difference! If it's cheaper to die cast you can then calculate how many parts you need to run before you start getting a return-on-investment on the tooling costs. What kind of accuracy do you need? What's the max dimensions of your part?
The tolerance is 0.001", and the part is about 1.5" x 3" (about 3.8cm x 7.62cm). Die casting would work for that in extremely mass numbers?
Hi Michael. Die casting is certainly a high-volume process. However, your tolerance requirements sound too tight to conventional die casting. Might also be a challenge for more specialist (expensive) casting processes like investment (lost-wax) casting. Do you know how similar parts are currently manufactured? Do you have any pics you could share with us? Perhaps casting+post machining is an option to get the tolerance you want, but this depends where the critical areas are. If you can post any images of your concept design or similar designs then it would be a useful basis for further discussion. Another thing about die casting - you will need to consider draft angles for mould-release. Also what material are you considering? Aluminum or zinc?
I thought you could also do steel with this; particular chorme moly 4140 or stainless steel 416. But yes, I will post an example of what I'm wanting.
Okay, here's the link: http://s1186.photobucket.com/albums/z37 ... ?start=all But yeah, I actually was considering part casting and machining for finer tolerances.
@ Linkdin Gopher: why wouldn't you suggest steel to be die casted? are there any other high volume casting processes you would suggest?
