place the tube clamp casting directly into the assembly as a raw casting, without any secondary machining or cutting. T e casting conversion costs 60% less than the weldment, accord- ing to Hammond, for an estimated annual savings of $8,000-$10,000. “I’m happy with the way it turned
Fig.1. Smith Foundry’s initial parting line location would have run across the top of the cast- ing for ease of core placement, but it would have affected the top hole and recessed diameter.
clamp, where the holes are placed, needed to be cast without draft so the part had a fl at surface for assembly. Smith Foundry solved the zero
draft requirement by forming the face of the casting with a core. “[Hammond] wanted a part with
no draft, which is always a chal- lenge, but in this case it worked out,” Pint said. “In all the critical
out,” he said. “T e part came to the shop and worked. And it has a good, fi nished look.” T e casting also came with a
areas, we found ways to eliminate draft totally through coring.” With this core design, the casting
was repositioned in the mold so the parting line cut across the width of the part, out of the way of where the spike would run through the clamp. “Once we got the design and part- ing line down, it was pretty problem- free,” Pint said. Initial samples were cast without diffi culty, and the part went into production shortly after approval. Besler Industries is able to
bonus improvement. T e original steel fabricated piece had a lot of play in the two outer bolt holes, which did not aff ect the part’s function but caused the assembly to rattle around, according to Hammond. “T e holes are much tighter now
and don’t wobble,” he said. “It wasn’t a requirement, but it’s a nice benefi t.”
ONLINE RESOURCE
Visit
www.metalcastingdesign.com to study other casting conversions.
June 2011 MODERN CASTING | 37
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