Worksheets for Manufacturing

Die Casting Analysis & Cost Optimization

Understanding geometric factors in manufacturing cost estimation

Die Casting

Cost Analysis

Geometric Optimization

Material Selection

Progress: 15%

Exercise 1 of 8 • 35 min remaining

0 / 0 points earned

Sections

Part Volume Calculation

12pts

analysis

medium

Die Casting Process Steps

15pts

Sequencing

easy

Wall Thickness Analysis

28pts

interactive

hard

Material Selection Interactive Quiz

35pts

material-selection

hard

Material Selection Quiz

14pts

Quiz

medium

Defect Analysis Sequence

21pts

Sequencing

hard

Cost Breakdown Analysis

25pts

synthesis

hard

Section Quiz: Die Casting Fundamentals

60pts

Section Quiz

medium

Points Summary

Current Total:

Section Max:

Review the lesson materials and consider the manufacturing constraints.

Exercise 1: Part Volume Calculation

analysis

12 points

Calculate the volume of the die cast part and understand its impact on material cost.

Instructions: Analyze the 3D model to determine the part volume. Consider how volume affects material usage and casting requirements.

Task: Analyze the 3D model below and calculate its volume in cubic millimeters (mm³). Use the dimensions visible in the viewer to make your calculations.

Loading 3D Model...

Volume Calculation

Part Dimensions (from 3D viewer):

Length

80 mm

Width

40 mm

Height

15 mm

Calculated Volume (mm³)

Calculate: Length × Width × Height

Cost Impact Analysis

Material Properties:

Aluminum Density: 0.0027 g/mm³

Material Cost: $0.003/g

Part Volume:

-- mm³

Material Mass:

-- g

Material Cost:

$--

Key Learning Points

Volume Impact

Part volume directly determines material usage and affects casting pressure requirements.

Cost Relationship

Material cost is linear with volume, making volume optimization critical for cost control.

Design Optimization

Consider hollow sections, ribs, and optimized wall thickness to reduce volume while maintaining strength.