Recently, we developed an investment casting die for a component, which we were manufacturing thus far from a stainless-steel washer. We would buy the stainless-steel washer and bore the center hole to the required size. In some of the washers, we would need to maintain the thickness by facing. Then the component would be mounted on our Vertical Machining Centre (VMC) for the hole drilling, milling and counter sinking operations. This part setting would run on the VMC for extended periods because stainless steel machining involves drill re-sharpening, cutter replacement and slow feeds. After removal from the VMC, all the holes required extensive deburring and cleaning, before assembly. Unfortunately, the component thus produced did not have a very high value when compared to the number of operations it required for completion. We converted the part to an investment casting using the die. The picture below shows both the components- one made from the washer and the other made from investment casting.
Advantages:
1. Castings are ready for assembly without any machining or finishing operation
2. It becomes cheaper when die cost is recovered.
3. VMC is available for machining more complicated parts, adding higher value
4. Castings can be produced with brand name or logo for better appearance
5. Mass production is possible in shorter time periods
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