[zmaker]

Hello,

We need a quote on this part. It is 6061-T6 aluminum that needs milled, drilled and tapped. This is a new part so it would be great to get a few prototypes made and tested before we place production quantities. Please quote prototype quantities of 4. Also, production quantities of 10, 50, 100 and 1,000.

If you have any suggestion for small changes that make the part easier to manufacture or less expensive, we will see if we can make that change before production. Thank you.

[dertsap]

If you have any suggestion for small changes that make the part easier to manufacture or less expensive, we will see if we can make that change before production. Thank you.

if you go into production you should look at getting them cast then machined , then the manufacturer could complete the part in one quick operation , both machine time and material costs will be greatly reduced

[zmaker]

Good idea, Dertsap. If you know of any good casting houses, we would like to ask them to quote as a casting with or without machining.

[dertsap]

check out your local directory for the local foundries , I'm sure there are a lot of company's who are close to you who would be more than happy to give you a quote .
and keep in mind to support your local manufacturers rather than out sourcing to cheap undesirable unqualified companies . it will pay off in the long term

[JD68]

Good idea, Dertsap. If you know of any good casting houses, we would like to ask them to quote as a casting with or without machining.

Here is one you might consider. They have been around a long time. They cast the torch used when the Olympics were in Atlanta.

http://www.whiteheaddiecast.com/

[HuFlungDung]

There are some very deep features on that part with radii that are too small to permit milling tools to 'make any time'. If all the internal (deep) features had a radius of .385", one could then probably do it with a 3/4" ballnose tool: just set up the toolpath and let the machine run. A 3/4" diameter tool is about the minimum that will work 3" deep without pulling a miracle out of.......the thin air

Whenever you add unequal radii at the bottom corners of a deep pocket, it just makes finishing more of a pain unless the design is such that a large diameter tool with a small radius tip can do the job, for example a 3/4" bull endmill with .1875" radius corners. I've not seen many designers that actually know what the tools look like and how to design to use the features of the tools.

[zmaker]

Your idea of a 3/4" diameter end mill with 3/16" radii is great, HuFlungDung. That way you could utilize the strength of a large diameter mill and still get the required internal radii. That end mill would allow you to do all the internal milling with it, and without tiny overlap that a ball end mill would require.

The 1/2" internal radii could be step milled with the same cutter. The finish is not at all critical in this area. The only reason these radii are 1/2" is to allow the external radii to be 3/4" for good looks. (These pieces are the switch pods on our new high-end zero turn riding mowers. They are at eye level, and mounted on motorcycle chromed handlebars, so they must look good.)

Thank you for your input. We are looking to get these parts made as soon as possible.

[dpryor]

ZMaker,
Machining is probably a good option for the prototypes or even up to 50 parts. Beyond that is when casting would begin to pay off. If the exterior surface finish is not too critical, sand casting might be a good option. The up front tooling cost is very low. Have you considered plastic or is this a high-temp application?

[zmaker]

Thanks for the suggestions to change all internal radii to be .375, and to change the part to a casting for higher quantities. It was originally designed to be a casting, and was changed to be a machined part. If sand casting tooling and lead time is not excessive, that does seem like a good option. Also, thank you for your quotes.

[briscoemach]

Anybody heared from this guy?

[zmaker]

Good morning,

We have been closed for several days for the holidays. Upon the advice of several people the part is being redesigned to make it more manufacturable. We are in the process of making those changes to the CAD files. After the changes, we will need to make sure all the mating parts and the switches, wires, etc. will fit. Then we will release the parts for manufacturing.

Thank you all for your input. We received 8 quotes. We will contact each person/company who quoted when we make the decision. We will not be able to make that decision until after January 4, 2010.

Happy New Year to all.