. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DeSign DetailS
Thick and thin sections align for sound risering and gating. • The design was adjusted to accommodate smooth transitions from thin to thick sections, leaving no isolated hot spots in the casting, which would otherwise create shrinkage porosities.
• Filling and solidification simulation predicted acceptable casting quality.
• Predicted potential porosity was located in the non-critical, unmachined area.
Smart selection of machined vs. as-cast features impacts cost and lead time. • Once form, fit and functionality are understood, the as-cast and machined features are determined depending on the capabilities of the casting alloy and process selected. Machined areas on the subrack are shown in red.
Full scale prototypes can be made using rapid prototyping. • An assembly interference check was conducted on a full-scale model produced via laminate object manufacturing against the 3-D master model.
METAL
Jiten Shah is president of Product Development & Analysis (PDA) LLC, Naperville, Ill., and a 25-year casting design and manufacturing veteran.
September/OctOber 2010 metal caSting DeSign & purchaSing 21
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