How would you tackle this part?

klemsontigers7 · Dec 20, 2020

I know it's not shown, but this part is about 2" long. How would you tackle this part? I know the walls are thin, is there some sort of stamping that would hold a tight tolerance? Tolerance is +/- .003 and the fillets shown do not have to exist, but those inner corners must be square. This will be a high quantity piece (1000-5000) after prototypes are finalized.

Milland · Dec 20, 2020

How thick is the part? If it's from thin sheet metal, look into photo etching (also known as photo chemical machining).

Photo Etching Process - YouTube

Photochemical Machining | Metal Etching | Elcon Precision

Strostkovy · Dec 20, 2020

I'd just stack laser cut parts. How you attach them depends on the application.

gbent · Dec 20, 2020

Hastelloy or bubble gum?

crazygoat · Dec 20, 2020

Milland said:
How thick is the part? If it's from thin sheet metal, look into photo etching (also known as photo chemical machining).

Photo Etching Process - YouTube

Photochemical Machining | Metal Etching | Elcon Precision

That must be the 2" he is talking about?

thermite · Dec 20, 2020

gbent said:
hastelloy or bubble gum?

SYP

No machining needed.

Just genetically re-engineer the tree to produce them as modified seeds.

Milland · Dec 20, 2020

crazygoat said:
That must be the 2" he is talking about?

Fair point. Eh, it's a conventional milling job then, isn't it? For such a small run, I don't think trying to stamp or extrude it makes sense (but I've been wrong before).

Strostkovy · Dec 20, 2020

I may or may not be an idiot for assuming this was a cross section of a round object.

In any case, drawing up something you don't know how to manufacture is a common engineering mistake.

Chances are a brake formed piece of sheet metal or commonly available extrusion could do the job if it were designed with that in mind.

Ralph_P · Dec 21, 2020

The diagram is .011 wider at the bottom. That might make it more difficult. I assume it's in inches.

thermite · Dec 21, 2020

Ralph_P said:
The diagram is .011 wider at the bottom. That might make it more difficult.

Not sure it is.

Note the placement of the lines. Is he showing the width required of the flat - before edge radii, bend, chamfer, "don't care"?

Seems so.

crazygoat · Dec 21, 2020

thermite said:
Not sure it is.

Note the placement of the lines. Is he showing the width required of the flat - before edge radii, bend, chamfer, "don't care"?

Seems so.

Good catch. I didn't notice that at first look.

Milland · Dec 21, 2020

crazygoat said:
Good catch. I didn't notice that at first look.

Not an ideal drawing. I'd rather have the lines/dimensions to the outside, and a radius callout. And not over dimension, either...

[All the views would be nice, too. And material. And...]

gustafson · Dec 21, 2020

Too many things we don't know, material, flatness.....

several on a sheet drill holes in one vise mount to fixture in the next

might be able to flip it to chamfer
figure out how to cut the tabs

Mr.M · Dec 21, 2020

If it is aluminum, I would do them in strips to allow 3 to be made at a time. OP10 machine the .370w and CR, flip to OP20 and machine the .301w slot and cut to length. If the volume will for sure be closer to 5000eau I would make a fixture plate to do the same thing but to be strips that use the full X travel of the mill.

AARONT · Dec 21, 2020

I'm thinking vacuum fixture. If you can have stock face on one side, this would be a 1OP part.

DDoug · Dec 21, 2020

Mr.M said:
If it is aluminum, I would do them in strips to allow 3 to be made at a time. OP10 machine the .370w and CR, flip to OP20 and machine the .301w slot and cut to length. If the volume will for sure be closer to 5000eau I would make a fixture plate to do the same thing but to be strips that use the full X travel of the mill.

If it's aluminum....extrude it.

mneuro · Dec 21, 2020

Strostkovy said:
I'd just stack laser cut parts. How you attach them depends on the application.

I would do the same thing but EDM.

Milland · Dec 21, 2020

digger doug said:
If it's aluminum....extrude it.

Calls out .003" tolerances. I imagine a good extruder could meet that, but I've seen enough variation in custom extrusions that I'd just mill it from sheet.

michiganbuck · Dec 21, 2020

klemsontigers7, don't be offended by some of the posts but do come back and tell the rest of the needed information.

The guys will give good information with having enough to go on.
Some might even offer to run the part..perhaps give a quote you cant pass.

Mr.M · Dec 21, 2020

digger doug said:
If it's aluminum....extrude it.

Yes, if you can get that qty done cost effectively and they can hit the tolerance, absolutely.

How would you tackle this part?

Plastic

Diamond

Titanium

Diamond

Stainless

Diamond

Diamond

Titanium

Stainless

Diamond

Stainless

Diamond

Diamond

Cast Iron

Stainless

Diamond

Cast Iron

Diamond

Diamond

Cast Iron

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