Casting Study: Bolt Guide – Remington Powerhammer

A value analysis on the Remington Powerhammer targeted the bolt guide for cost reduction. The bolt guide was originally designed as a screw machined steel component. After prototyping and testing, engineers decided that die casting and ZA-8 provide the design flexibility and tensile strength required. Die casting allowed several features to be designed into the bolt guide. Ribs are cast onto the surface holding a plastic hand grip in place. Additionally, two grooves are cast into the guide’s neck which fits into a steel sleeve. The sleeve is then roll pressed to fit the neck contours for a secure fit. Tumble deburring is the only secondary operation performed on the bolt guide. By taking advantage of ZA-8’s strength and the design flexibility of die casting, manufacturing cost was cut in half. This cost saving is realised through the elimination of machining and the associated labour.