Posted by: manoj18 ® 03/14/2007, 08:07:01 Author Profile eMail author Edit

Hello friends, I have a couple of questions 1) How do I determine the minimum wall thickness of a complex component/part ( made in aluminum ASTM 84B) which is manufactured by pressure die casting process? 2)If there are two components which assemble onto each other by means of threads(made in aluminum)& they are made from the same metal, is there any chance that the threads will wear out faster? Is there any process by means of which I can strengthen the threads of the above mentioned two mating components so that they have a longer life? thanks,

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Re: Pressure die casting
Re: Pressure die casting -- manoj18	Post Reply	Top of thread	Forum

Posted by: Kelly Bramble ® 03/14/2007, 09:40:18 Author Profile eMail author Edit

"How do I determine the minimum wall thickness of a complex component/part ( made in aluminum ASTM 84B) which is manufactured by pressure die casting process?" Contact the die casting manufacturer... While your at it, ask them to review your design concept for any problem areas and provide you with feed back. "If there are two components which assemble onto each other by means of threads(made in aluminum)& they are made from the same metal, is there any chance that the threads will wear out faster? Is there any process by means of which I can strengthen the threads of the above mentioned two mating components so that they have a longer life?" If you expect that the parts will be assembled and disassembled multiple times, or therer is significant fatique or static stress, or you only design quality products. Design for and use a threaded insert at the threaded areas. There are many kinds: Helicoils, Tangless, etc.. Manufacturing tends to like tangless because they can easily remove and replace them for rework. You might consider using stainless fasteners since the threaded inserts will likely be stainless as well. Modified by Kelly Bramble at Wed, Mar 14, 2007, 10:17:00

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Re: Re: Pressure die casting
Re: Re: Pressure die casting -- Kelly Bramble	Post Reply	Top of thread	Forum

Posted by: manoj18 ® 03/15/2007, 01:52:03 Author Profile eMail author Edit

Thanks Kelly. a few more questions... Contact the die casting manufacturer... While your at it, ask them to review your design concept for any problem areas and provide you with feed back. Can this be taken care of during the design stage itself ? & how? If you expect that the parts will be assembled and disassembled multiple times, or therer is significant fatique or static stress, or you only design quality products. Design for and use a threaded insert at the threaded areas. There are many kinds: Helicoils, Tangless, etc.. Manufacturing tends to like tangless because they can easily remove and replace them for rework. You might consider using stainless fasteners since the threaded inserts will likely be stainless as well. The parts will be assembled & disassembled once in 3 months on an average. It also could be once in Six months. Moreover, although the insert will be made of steel, the mating component will be made from Aluminum & as these will be different materials in contact with each other, the more ductile material will tend to wear out faster(threads),is'nt it?

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Re: Re: Re: Pressure die casting
Re: Re: Re: Pressure die casting -- manoj18	Post Reply	Top of thread	Forum

Posted by: Kelly Bramble ® 03/15/2007, 09:35:09 Author Profile eMail author Edit

"Can this be taken care of during the design stage itself ? & how?" Typically, during the design phase ytou will already have a couple of casting suppliers on board. If not, complete your preliminary design and submit your drawing to them and have a meeting to discuss challenging areas of your design. If your are in a corrosive environment use a thread locker or primer when the threaded inserts are installed. This will keep out the Oxygen and prevent corrosion. If you use aluminum, it will wear out faster than the steel. Why do you need to use use aluminum bolts?

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Re: Re: Re: Re: Pressure die casting
Re: Re: Re: Re: Pressure die casting -- Kelly Bramble	Post Reply	Top of thread	Forum

Posted by: manoj18 ® 03/16/2007, 02:56:03 Author Profile eMail author Edit

Kelly, Attahced is the drawing of component assy for your reference. Please comment. thanks, manoj

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Re: Re: Re: Re: Re: Pressure die casting
Re: Re: Re: Re: Re: Pressure die casting -- manoj18	Post Reply	Top of thread	Forum

Posted by: Kelly Bramble ® 03/19/2007, 12:41:39 Author Profile eMail author Edit

The design seems simple and robust. I'm sure your components will require post-cast machining. I would detail and send the parts to your casting vendors for feed back. Be sure to allow at least .060 inch (or what every the machine shop performing the cutting recommends) extra material within those areas requiring post machining operations.

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