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DESIGN GUIDE & TOLERANCES - Aluminiumsstøbning, Extruderet og trykstøbt aluminium
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Forside › Konstruktion & Prototyper › DESIGN GUIDE & TOLERANCES
DESIGN GUIDE & TOLERANCES
Tilbud fra APC ApS er baseret på tegninger på engelsk med fyldesgørende informationer:. a) Materialespecifikation VIGTIG (Se evt. nednfor pkt 13). Da materiale normer er anderledes i Kina SKAL Normer uddybes med procentuel grundstofindhold.
b) 2D og 3D tegninger med angivelse af vægt af emne. Alle specifikationer skal være på engelsk.
c) Evt støbetegninger. Skal med hvis emnet leveres ubearbejdet.
d) Tolerancer (Se evt. nedenfor).
DESIGN GUIDE & TOLERANCES
Te ultimate success of te casting design depends on te communication between te designer and foundry engineers. When te foundry is properly informed of part requirements, there is usually a compromise of specifications that will allow for maximum compliance to print specifications and finish part design.
As-cast tolerances of angles is mainly a function of te part design and their ocation in casting. They range from +/- 1/2 degree (considered minimum) for well supported positions to +/- 2 degree where existing distortion could be expected. Inclusion of gussets and ribs normally minimizes distortion and many sections can be mechanically straightened.
3.Flatness, Strengteness and Roundness
Possible Thickness Section Sink per Face of Casting
Straightening adds cost, but sometimes cannot be avoided. Te actual straightening costs are often dependent on te tightness of te tolerance specified, so do not specify tighter flatness, straightness, roundness, or other requirements than you actually require. (Cheonseng typically straightens parts using die sets that will be included in your tooling price.)
4.Size and Weight Range
Size and Weight. Part size and weight are te most critical factors in determining part cost because mold capacity is limited by both size and weight. Te more pieces that can run on a mold, te lower te part cost. Unnecessary mass should always be removed by correct engineering practices to reduce part weight.
80 to 120 RMS are average.
Making a good hole in a casting is dependent on te integrity of te shell. Te ratio of holediameter to length is important in determining what can be offered. Blind holes must have aradius at te top and te bottom of te hole to insure that a strong core is built for castingpurposes and to insure te best possible casting
7. Number of Gates
When possible, parts should be designed so that a single gate can feed te part. This will generally yield more pieces per mold and reduce te pour weight per mold.
Cheonseng builds gate grind fixtures for virtually all parts produced that require gate grind. When possible, te part should be designed so te gate can be put on flat surface rather than curved surface. Gate grind tolerances are listed from least to greatest cost.
1. Break-off witness (same alloys)
2. 0.20-0.50mm high witness
Heat treatments are used to control hardness, mechanical properties, corrosion resistance, and surface treatments. Unless otherwise indicated, all alloy steels are quoted with a normalize or anneal. All 300 series stainless steels and 17-4PH are quoted with a solution anneal.
Cheonseng performs a 100% visual inspection, However, if dimensional verification is required, a sampling plan and process control is less expensive than 100% gaging of each part. Fixed gages such as "go-no-go" are less expensive to use than gages with dial indicators. (Important: Whenever custom gages are used, there should be identical gages at Cheonseng and at te customer's plant.)
All sample investment castings are non-destructively tested in order to establish first article quality. However, this is generally not required on production commercial investment castings; doing so will add costs. Te following non-destructive tests are listed from least to greatest cost:
Chemical Certification can be provided at no extra cost. Mechanical Property Certification adds to cost, so it's best to consider a combination of Chemistry and Hardness Certification instead. Marking each casting with heat number also adds to te cost. Investment casting in lot numbers may be a good tracability option for commercial parts.
12. Tooling & Cavities
If te design contains features that will raise scrap or rework rates (and te piece price), te Cheonseng Estimating Engineer will recommend design modifications to keep te piece price down.More cavities means higher tooling cost, but lower piece price. Configurations that do not allow metal cores to be drawn must be treated in one of te following ways:
1. Collapsible Cores - Lowest piece price, higher tooling cost.
2. Loose inserts - Best for low volume parts.
3. Multipiece Wax Assemblies - Best for certain configurations, but tolerance control suffers.
4. Soluble Cores - Requires additional die and labor.
5. Pre-Formed Ceramic Cores - High cost for specialized shapes.
Alloys are listed from least to greatest cost:
1. Carbon and Low Alloy Steels
8620, 4140, 1020, 1035are best choices
2. 17-4PH and 400 Series Stainless Steel
17-4PH & CA-15 (410) are most frequently poured
Do not specify 416 unless necessary for machinability
3. 300 Series Stainless Steel
CF-8 (304), CF-8M (316) are best choices
Do not specify CF-16F (303) unless necessary for machinability
Costs vary widely depending on grade
5. Nickel Base Alloys
Alloy C and X are best choices
6. Cobalt Base Alloys
All grades pour well - Choice is based on end use and cost
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