. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DESIGN DETAILS
Gradually transitioning thick sections to thin ap- pendages promoted better castability and longer product life cycle by reducing stress concentration. Generous fi llets and corner radii were integral to
the casting design. Sharp corners tend to produce tears due to heat concentration. Smooth thick-to- thin transitions allow directional solidifi cation, as well as less turbulent liquid metal fl ow, providing better quality castings.
Cored features supplied weight savings and elimi- nated bore drilling. The rifl e scope includes:
• as-cast cored holes • wiring passageways from the control box to the battery pack. Core features are determined by the
cored-hole diameter, section thickness, ease of wax pattern making, ability of the slurry to fl ow and fl uidity of the cast alloy.
Intricate gating and risering system allowed liquid metal to fl ow into complex shapes and thin-wall sections. The pre-heated ceramic shell in investment
casting enabled the thin-walled casting con- fi guration with cored holes.
Jiten Shah is president of Product Development & Analysis (PDA) LLC, Naperville, Ill., and a 25-year casting design and manufacturing veteran.
JULY/AUGUST 2011 METAL CASTING DESIGN & PURCHASING 23
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