Cad Drawing, Manufacturing Techniques?

[walker]

Hello all,

here's a model i made on solid edge, its some sort of stub axel, not sure what its off.

Does anyone know the manufacturing methods that would be used to manufacture it?

any help greatly appreciated,

Andrew

[Si-man]

Milling, drilling, turning??

that what you mean?

[walker]

yeah, that sort of thing, but im no dumb ass.

Would it be machined from a casting?

other option is to have two parts welded together

Andrew

[Si-man]

Could machine that from a bit of stock, lots of labour time, money though.

Casting sounds like the best way.

Im not sure what one of these parts actually looks like in real life.

[walker]

bascally itsa simplified verion of what ur slave cylinder/hub bolts onto on car, they're everywhere!! i was just hoping somen could tell me eactly how they are made??

Andrew

[Si-man]

cast going for that one. then later machined to shape.

Could possibly use spark eroding aswell, as you can get any shape you want with that method

Edited November 28, 2007 by Si-man

[OD404]

Forging, or casting for the main body, finished by milling and drilling. The shaft could be turned separately and friction welded to the body. Alternatively you could look at die casting or injection molding (you haven't really given an idea of its use so no comments about plastic being too weak) but they would be expensive due to the intricate molds required.

Or (assuming plastic isn't appropriate) you could look to rapid manufacture techniques such as laser sintering (and dmls).

[walker]

so im guessing most automobiles will used cast items, as forged would cost a lot more. Obviously forged steel has a higher strength to weight ratio than cast iron, so the cast iron version would be bulkier?

Andrew

[OD404]

so im guessing most automobiles will used cast items, as forged would cost a lot more. Obviously forged steel has a higher strength to weight ratio than cast iron, so the cast iron version would be bulkier?

Andrew

If you used the same design for each material there wouldn't be much of a mass difference (same densities), but the steel one would be stronger. Therefore you could remove material to make it lighter. Cast iron is probably the most common material found for those parts due to cost (or lack there of).

[Heatsink]

As a first step be sure to have the requirements of the design noted, the function is carries out when part of the car. Then an appropriate manufacturing process can be picked out to fulfill the requirements.

Highly stressed part or not.

Any surfaces that need to be accurately made for fitting other parts onto.

Etc, building into a thorough Design Specification for the item, cost, performance... I'm sure you're already familar with Design Specs.

In the photo, the example has been machined (the shiny bits) only where the accurate finish is required. As a mass production part, it must have worked out more cost efficient to factor in the high one off cost of the tooling for casting, with the necessary machining only on the important areas for threads and accurate mating of other items.

Steve

[walker]

Thanks for your help. Just out of curiosity, what would be the outcome of casting a component out of steel, not pure iron?

Andrew

[TheCircus]

POWER DRILL AND GLUE.

[Heatsink]

Thanks for your help. Just out of curiosity, what would be the outcome of casting a component out of steel, not pure iron?

Andrew

I'd have a look on Wikipedia to uncover all the detail on how Steel and Iron compare for mechanical properties and relevant processes of manufacture

[future orange 660]

don't forget the internal properties once cast.

as for the specific process. there are many to choose from.

as long as you justify your choice, the objective is to find out for yourself about processes.

f it is just one, i would ignore cost.

investment casting would possibly be ok for a one off.

[Adrian]

i cant see the pic but if its some sort of axel its probs just machined from a single billit or if theyre realy fancy maybe investment casting???? very expensive i suppose though..... im at college so the comps are crap and wont open the pic... lol ill wait till i get home

edit: ah i see someones already mentioned investment lol

Edited November 29, 2007 by aim@me

[PaRtZ]

i guess you could machine the whole damn thing but as its been said, easier to cast and then finish off

not sure how you'd clamp it in a lathe to turn the end bit though unless you had some extra material to clamp it on, and then remove it afterwards meh..

[Bionic Balls]

i'm gonna go with od404 and say forged then finished...

people do not cast steel very often...it's very expensive and not worth it

[OD404]

not sure how you'd clamp it in a lathe to turn the end bit though unless you had some extra material to clamp it on, and then remove it afterwards meh..

Lathe it from a bar, use a parting tool to cut the finished piece off, then friction weld to the body.