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Screen shot below shows the added cast hole due to Magma predicting a large porosity in the solid section.


Because simulation software predicted a large section of porosity in the solid section at the top of the hydrant, a hole was added to aid in solidification, as indicated by the arrow at right.


to achieve a part that was castable at a reasonable cost. While the original design required a five-piece core as- sembly, the team was able to whittle that down to two. The reduction


Online Resource


Visit www.metalcastingvirtuallibrary.com/afscaps/caps.aspx tofor a tool to help select the proper casting process for your application.


was instrumental in achieving a 37% price break from the original design. One of the critical elements of


the redesign and reduction of cores was a change in the drainage valve


originally situated at the bottom rear of the casting. During rain storms or other precipitation events, hydrants can collect water, which needs to be released from the body. The drain hole originally put in place by Sigelakis and his team was not in an ideal spot to be cast. According to Applegate, the 0.5-0.625-in. hole had to be removed to achieve the simpler core package.


42 METAL CASTING DESIGN AND PURCHASING


JULY/AUGUST 2011


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