. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Details
Modeling Tools Aid in Design of Wheel Hub Jiten Shah, Product Development & Analysis, Naperville, Illinois CASTING PROFILE
Casting Process: Sand casting. Material: Ductile iron. Application: Heavy truck. Dimensions: 12 x 12 x 10 in., 30 lbs.
and longer lead times due to rework and scrap. Here, a sand cast ductile iron hub casting for the heavy truck industry undergoes product development and design optimization to meet stringent quality requirements at minimum weight.
R
ather than specify an entire casting be free of any flaws and discontinuities, establishing critical high stress areas using finite element analysis (FEA) and casting process modeling tools can avoid higher cost, poor consistency
Determining part orientation and parting plane: • Molten metal cools as it fills the mold cavity. The re-oxidation products and inclusions, which are typically lighter in density, tend to float to the top and get trapped. Part orientation and parting plane determination are keys to avoiding these trapped inclusions.
• This wheel hub was oriented so the overall cross sectional area shrinks as it moved away from the parting plane, which compensated for the hydraulic frictional forces of the liquid metal and kept the local flow velocities high enough to avoid stagnant spots or locations.
• Metal splashing was avoided by designing the in-gates at a location closest to the bottom as possible.
The cast wheel hub is used on heavy trucks.
March/april 2010 Metal casting Design & purchasing 21
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