Figure 2 Cast Iron Tool Holder (dimension: inch) 2.00 6.00 MacBook Pro

To make 200 cast iron tool holders as shown in Figure 2 per order, two orders per year expected, and the inside hole surfaces should be smooth, what manufacturing processes would you suggest for the part.

a)Machining processes from the 2X1.5 inch iron bar stocks with no initial tooling cost.

1. cut the bar into 6 inch long pieces with bandsaws
2. mill all the flat surfaces on a milling machine
3. drill the two holes on the same milling machine or a drill press

b)

1. sand casting, which has much lower initial tooling cost than die casting and reasonable production rate.
2. drill to make the smooth inside surfaces of the two holes on a milling machine or drill press.

c)

1. forging process with rounded edges and corners.
2. drill the two holes on a milling machine or drill press.

d)die casting, which can make the part in high production rate with smooth surface and precise dimension