In the early 50's, Altec produced aluminum 808 horns that were casted in two pieces and bolted together.
After only a few years, Altec went with an one-piece design. Upon closer inspection, the one-piece design appeared to be two halves welded together.
After the "success" of the cast WP12027 project, I decided take a deep dive on designing a cast aluminum 808. From a casting perspective, the 808 was much more technically challenging. Casting requires certain minimum wall thicknesses, features and draft angles. After weeks of modeling efforts and a couple dozen models later - Voila.
Two pieces with tabs. Bolted together to form the final assembly.
Two pieces. No tabs. Welded together to form the final assembly.
The biggest drawback of the two piece with tabs design is the roundness of the throat. It's very difficult to maintain perfect roundness and concentricity where the two halves are machined with manufacturing variations/tolerances and then come together. Can pair up two halves, machined and maintain the pairing - not easy to do in practice. (I prefer the bolted together design. It looks so archaic and cool.) For the single piece design where the two halves are welded together, the throat roundness can be maintained by boring it out to dimension after welding.
Anyway, which of the two designs do you guys prefer?
After only a few years, Altec went with an one-piece design. Upon closer inspection, the one-piece design appeared to be two halves welded together.
After the "success" of the cast WP12027 project, I decided take a deep dive on designing a cast aluminum 808. From a casting perspective, the 808 was much more technically challenging. Casting requires certain minimum wall thicknesses, features and draft angles. After weeks of modeling efforts and a couple dozen models later - Voila.
Two pieces with tabs. Bolted together to form the final assembly.
Two pieces. No tabs. Welded together to form the final assembly.
The biggest drawback of the two piece with tabs design is the roundness of the throat. It's very difficult to maintain perfect roundness and concentricity where the two halves are machined with manufacturing variations/tolerances and then come together. Can pair up two halves, machined and maintain the pairing - not easy to do in practice. (I prefer the bolted together design. It looks so archaic and cool.) For the single piece design where the two halves are welded together, the throat roundness can be maintained by boring it out to dimension after welding.
Anyway, which of the two designs do you guys prefer?
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