Honorable Mention Transmission—Main Housing
Mercury Marine, Fond du Lac, Wisconsin
Material: XK 360 aluminum. Process: High pressure diecasting. Weight: 52 lbs. Dimensions: 15 x 13 x 14.25 in. Application: Transmission for hybrid electric sports car.
Converted From: Sand casting.
• T e casting supplier developed the gating for the part using casting process modeling with multiple die orientations in order to meet quality and pressure tight requirements.
• T e diecast design was optimized for cast datums and machine locators that provided the best repeatability in a large four-slide die tool.
Brake Pivot Bracket Signicast Investment Casting, Hartford, Wisconsin
Material: Weldable cast B-grade carbon steel.
Process: Investment casting. Weight: 1.68 lbs. Dimensions: 3 x 3.75 x 8 in. Application: Parking brake for agriculture equipment.
• No machining is required on this steel casting due to design modifi cations that allowed all features to be cast within draw requirements. Due to the dimensional stability of the process, holes on tabs and two nut pockets were cast-in, eliminating machining and tapping operations. A rib aids micro-switch assembly alignment.
• T e casting supplier utilized wax rapid prototyping for initial samples to develop design viability.
May/Jun 2012 | METAL CASTING DESIGN & PURCHASING | 33
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