. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Details


10-Piece Weldment Converted to Single Casting


Jiten Shah, Product Development & Analysis, Naperville, Illinois CASTING PROFILE


Casting Process: Permanent mold casting. Material: Brass. Application: Material handling/steering. Dimensions: 29.82 lbs., 10 x 8.5 x 6.7 in. (4.45 kg, 25.4 x 21.59 x 17.02 cm).


Permanent mold process and use of pockets reduce sidewall thickness. • Weldments are limited to the availability of plate thickness, and their material is limited to avail- able chemical composition in the marketplace. Casting allows designers to choose an odd-size thickness with customized com- position and properties to design for service loads without adding unnecessary material.


• The component’s side walls feature pockets produced with cores, which reduce part weight. Permanent mold castings offer better dimen- sional accuracy and reproducibility, surface finish and near-ney-shaped features than sand casting.


Frame mounting A


steering linkage component for a pallet truck was converted from a 10-piece pre-fabricated assembly that required 19 weld joints and four bushings. The conversion eliminated the need for stress relieving and some machining, while reducing part weight by 10% and facilitating the mounting of additional components. The permanent mold process


allowed configurations that included cast-in holes, bosses and slots and eliminated the need for pivot shafts, swinging rods, wire harness clips and adjustment cams.


Weldment


Casting 18 Metal Casting Design & PurChasing January/February 2011


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