We have been running thousands of these simple parts a year and decided to get a quote on an extrusion profile, and to my surprise the die cost was only $1,150. The extrusion will cut our material cost in half and machining time by almost the same. Ordered the die and waiting on the first 10 bars to arrive in the next 3-4 weeks.
Was planning on running them in 2 double vises 3 at a time per vise with 24" long soft jaws cut to hold the 5.6" profile. One thought is to gang a bunch up in the bridgeport and take a skim cut on the 2.95" "legs" just to even them up to get a consistent grip on the soft jaws to drill and face each part.
We would also like to chamfer (edge break) them while were at it to avoid tumbling but with that much profile variation it may be tough to get a consistent looking chamfer.
Advise?
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Was planning on running them in 2 double vises 3 at a time per vise with 24" long soft jaws cut to hold the 5.6" profile. One thought is to gang a bunch up in the bridgeport and take a skim cut on the 2.95" "legs" just to even them up to get a consistent grip on the soft jaws to drill and face each part.
We would also like to chamfer (edge break) them while were at it to avoid tumbling but with that much profile variation it may be tough to get a consistent looking chamfer.
Advise?
