This document summarizes the method report for a sand cast aluminum part called a SpacingBracket1. Key details include:
- The part is made of aluminum alloy AlSi6 using sand casting with a yield of 66.58%.
- The mold is made of green sand and contains the part cavity as well as two CO2 cured sand cores and two cylindrical side feeders to compensate for metal shrinkage.
- The gating system uses a rectangular pouring basin, cylindrical sprue, and two cylindrical gates to fill the mold cavity.
- Production of 1000 parts is estimated to cost a total of $136 including $132 in labor costs based on a $4 cost for the aluminum.
This document summarizes the method report for a sand cast aluminum part called a SpacingBracket1. Key details include:
- The part is made of aluminum alloy AlSi6 using sand casting with a yield of 66.58%.
- The mold is made of green sand and contains the part cavity as well as two CO2 cured sand cores and two cylindrical side feeders to compensate for metal shrinkage.
- The gating system uses a rectangular pouring basin, cylindrical sprue, and two cylindrical gates to fill the mold cavity.
- Production of 1000 parts is estimated to cost a total of $136 including $132 in labor costs based on a $4 cost for the aluminum.
This document summarizes the method report for a sand cast aluminum part called a SpacingBracket1. Key details include:
- The part is made of aluminum alloy AlSi6 using sand casting with a yield of 66.58%.
- The mold is made of green sand and contains the part cavity as well as two CO2 cured sand cores and two cylindrical side feeders to compensate for metal shrinkage.
- The gating system uses a rectangular pouring basin, cylindrical sprue, and two cylindrical gates to fill the mold cavity.
- Production of 1000 parts is estimated to cost a total of $136 including $132 in labor costs based on a $4 cost for the aluminum.
This document summarizes the method report for a sand cast aluminum part called a SpacingBracket1. Key details include:
- The part is made of aluminum alloy AlSi6 using sand casting with a yield of 66.58%.
- The mold is made of green sand and contains the part cavity as well as two CO2 cured sand cores and two cylindrical side feeders to compensate for metal shrinkage.
- The gating system uses a rectangular pouring basin, cylindrical sprue, and two cylindrical gates to fill the mold cavity.
- Production of 1000 parts is estimated to cost a total of $136 including $132 in labor costs based on a $4 cost for the aluminum.
Cast Metal Aluminum - AlSi6 Casting Process Sand Casting Density 2400 kg/m Liquidus 632 C Order Quantity 1000 Yield 66.58 % Part Dimensions 67.5 mm X 20 mm X 15 mm Part Surface Area 43.08 cm Min. Thickness 0.34 mm Max. Thickness 3.6 mm Part Weight 18.17 g Part Volume 6.75 cm Mold Mold Material Green Sand Density 1550 kg/m Dimensions 81 mm X 77.3 mm X 42.02 mm Parting Orientation Horizontal Number of Cavities x Draw Distance 7.5 mm Min. Cavity-Wall Gap 14.3 mm Metal / Sand (weight) 15.02 % Min. Cavity-Cavity Gap 23.8 mm Metal / Sand (Volume) 8.66 % Page 1 of 3 9/13/2014 file:///F:/05-09/02092014New/SpacingBracket1/SpacingBracket1%20(1).htm Cores Core 1 Material CO2 Cured Density 1770 kg/m Weight 2.77 g Volume 1.57 cm Core 2 Material CO2 Cured Density 1770 kg/m Weight 1.08 g Volume 607.47 mm Feeders Total Feeding Weight 12.87 g Feeding Yield 73.85 % Feeder 1 Orientation Side Shape Cylindrical Weight 7.61 g Volume 2.83 cm Diameter Top 13 mm Diameter Bottom 13 mm Height 14.59 mm Number of Necks 2 Neck 1 Shape Rectangular Length 10.5 mm Length at Part 5.94 mm Length at Feeder 5.94 mm Width at Part 5.94 mm Width at Feeder 5.94 mm Neck 2 Shape Rectangular Length 10.35 mm Length at Part 5.94 mm Length at Feeder 5.94 mm Width at Part 5.94 mm Width at Feeder 5.94 mm Feeder 2 Orientation Side Shape Cylindrical Weight 5.25 g Volume 1.95 cm Diameter Top 10 mm Diameter Bottom 10 mm Height 14.48 mm Number of Necks 2 Neck 1 Shape Rectangular Length 12.18 mm Length at Part 5.9 mm Length at Feeder 5.9 mm Width at Part 5.9 mm Width at Feeder 5.9 mm Neck 2 Shape Rectangular Length 11.78 mm Length at Part 5.9 mm Length at Feeder 5.9 mm Width at Part 5.9 mm Width at Feeder 5.9 mm Gating Overall Pouring Temperature 730 C Mold Filling Time N/A Total Metal Head 21.8 mm Average Fill Rate 65.56 g /s Gating System Weight 17.23 g Gating Yield 67.83 % Total Poured Weight 54.57 g Sprue 1 Pouring Basin Page 2 of 3 9/13/2014 file:///F:/05-09/02092014New/SpacingBracket1/SpacingBracket1%20(1).htm Shape Rectangular Dimensions 20.52 mm X 20.52 mm X 6.84 mm Sprue Shape Cylindrical Height 21.8 mm Top Diameter 12.65 mm Bottom Diameter 10.12 mm Sprue Well Diameter 13.68 mm Height 9.58 mm Gates Number of Gates 2 Total Gate Area 40.21 mm Total Gating Weight 1.08 g Total Gating Volume 400.16 mm Gate 1 Shape Cylindrical Length 18.45 mm Diameter 5.06 mm Gate 2 Shape Cylindrical Length 15.35 mm Diameter 5.06 mm Costing Tooling Cost 0 Rs Energy Cost 0 Rs Cast Metal Cost 4 Rs Labor Cost 132 Rs Indirect Material Cost 1 Rs Total Process Cost 132 Rs Total Material Cost 4 Rs Total Cost 136 Rs Report Generated by AutoCAST Page 3 of 3 9/13/2014 file:///F:/05-09/02092014New/SpacingBracket1/SpacingBracket1%20(1).htm