Designing the gating system and then simulating the actual casting itself utilizing MAGMASOFT simulation software proved to be quite helpful. Upon running the simulation I was given results for potential problems in the casting; including (but not limited to) air entrapment, porosity, shrink, and solidification time gradients. Based on this data I was able to make slight modifications to the gating sys- tem and re-run the part, after a couple iteration I ended up with a sound gating and casting design.
Pattern
Once I had verified the casting and gating design with MAG- MA it came to the point to actually make the pattern for the parts. I opted to construct a matchplate pattern to make the parts. Having a rapid prototyping machine at the Pitts- burg State University Technology Center served to be quite useful with this project, because the detailed features of the part posed no difficulty for the machine to replicate. Upon uploading the pattern pieces into the rapid prototyping ma- chine’s database they were all made in a matter of hours, ac- curate to design. I aligned the pattern parts on the matchplate according to the layout I had simulated and secured them in place using small aligning pins and adhesive.
Casting
Now that the pattern was finished I made the molds, cast the parts, cleaned off the castings, and began preparing the heat-treating of the parts. As previously mentioned I opted to perform a T6 heat treatment which would give the hub an increase in strength while not making it brittle.
Machining
place overall out of the 75 teams present. REFERENCES
The machining was quite straight forward because the re- inforcing ribs on the sides of each part allowed for the vice to securely hold the part in place. The final opera- tions consisted of boring the main hole to press-fit the bearings into, also drilling and tapping the three points which would secure the hub to the suspension arms. Af- ter the bearings were inserted, the hubs were mounted on the vehicle and our testing began in preparation for the competition. While at the competition the hubs performed without any sign of strain, and our team went on to take 5th
Askeland, D. and Phule, P. The Science and Engineering of Materials fourth edition. Thomson Brooks/Cole (2003) Schleg, Frederick. Technology of Metalcasting. American Foundry Society (2006)
Rear Axle
Front Axle
Original Hub 64
Redesigned Hub International Journal of Metalcasting/Winter 10
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