design details D
Generous fi llet, radii and transitions make for better casting manufacturing and a sounder component. • During molding, sand fl ows into a pattern better when a part utilizes smooth transitions and generous fi llets and radii. Better fi lling of the pattern results in sound- er mold sections, which otherwise may break off or become dislodged. Bad molds lead to a scrapped or dirty casting with sand inclusions. Smoother transi- tions also allow reduced turbulence of liquid metal while fi lling into the mold cavity.
• Smooth transitions at T, L, X and Y junctions are required for producing thermally-balanced castings that are free of hot and cold tears.
Collaborating on parting line location helps in incorporating design features that reduce weight or add complexity. • An optimum parting plane allowed weight-reducing pockets to be incor- porated into the green sand mold, eliminating the need for cores.
Jiten Shah is president of Product Development & Analysis (PDA) LLC, Naperville, Ill., and a 25-year casting design and manufacturing veteran.
Sept/Oct 2011 | METAL CASTING DESIGN & PURCHASING | 19
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