. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Details
Rapid Prototyping Technologies Enhance Military Part
Jiten Shah, Product Development & Analysis, Naperville, Illinois CASTING PROFILE
Casting Process: Sand casting. Material: A356 aluminum. Application: Naval submarine. Dimensions: 12 x 12 x 18 in. Converted From: Fabrication.
tough military service environmental re- quirements for the subrack, such as shock and vibration, demanded an integrated ap- proach consisting of intelligent modeling, design, FEA-based analysis, process simu- lation and rapid prototyping technologies. The casting supplier supplied a conceptual model with casting orientation, parting and core/tool design to the OEM design engi- neers. Then, a master model consisting of machined part, rough casting and tooling geometries was developed for detail design.
B
y collaborating with the OEM design engineers using web-based tools, the casting supplier produced this casting conversion from a fabrica- tion that reduced product unit cost by 40%, component weight from 24.9 lbs. to 23.2 lbs. and production cycle time from 40 weeks to 14. The shape complexity and
Tighter dimensional tolerances are achieved with precision CNC machined composite tooling. • A urethane pattern was machined using a CNC mill directly off the master model 3-D CAD file, with tight core print clearances to achieve tighter dimensional control, as demanded by the military customer.
The casting customers wanted to reduce cycle time and cost by converting a fabricated subrack used on a Navy submarine to an aluminum sand casting.
20 Metal Casting Design & PurChasing sePteMber/OCtOber 2010
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