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


Smooth transitions with corner fillets and radii help avoid defects. • In designing sound castings, smooth transitions are required at L, T , X and Y junctions. Providing gener- ous fillets at these junctions helps avoid potential tearing, cracks and/ or distortion.


• The fillets and corner radii magni- tudes depend on the casting section thickness.


As-cast cored features eliminate extra machining. • Permanent mold chill casting, in which the mold is quickly cooled through quenching after each casting cycle, offers excellent dimensional accuracy, making it possible to design as-cast cored features for mounting and assembly. These features were machined on the weldment. • Bushings were eliminated with as-cast cored holes.


Jiten Shah is president of Product Development & Analysis (PDA) LLC, Naperville, Ill., and a 25-year casting design and manufacturing veteran.


January/February 2011 Metal Casting Design & PurChasing 19


METAL


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