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innovations CASTING


Conversion Breaks Ice for Start-Up


the menacing Arctic Shark, which is built for municipalities in cold-weather regions to break up ice on roadways. T e machine uses 20 metal wheels to claw away at frozen streets. Originally built as steel weldments, the wheels were expensive and labor-intensive. Converting to ductile iron castings slashed more than $300 from the cost of the wheel. “[T e cost savings] really made a


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diff erence,” Bearly said. “It’s now about $75 a wheel with all the machine work incorporated into it. I use 20 of those wheels per machine, so it certainly af- fects the bottom line.” Referred by a friend to iron caster Far-


rar Corp., Manhattan, Kan., Bearly said he spoke with President and CEO Joe Farrar on a Monday and was on his way to the casting facility by the end of the week to work on a solution. Farrar made design suggestions that would improve the manu- facturability of the part and ultimately reduce cost. “One of the challenges for a foundry is to work with the


casting saved Phil Bearly the money he needed to move his startup com- pany ahead. Ultramech, Loveland, Colo., builds


customer in the concept stage rather than after fi nal design,” Farrar said. “For instance, Bearly needed a right and left wheel because of the position of a keyway. We suggested putting two keyways in every wheel so any wheel could be left or right.” Grade 80-55-06 ductile iron proved


strong enough to handle the weight load of the entire fi nished machine and the constant abrasion against thick ice. “We looked at the application and


recommended heat treating was not necessary, so we were able to save Bear- ly money there,” Farrar said. “We were also able to lighten the part consider- ably and still meet strength require- ments, saving him material cost.” T e fi nal 16-in. casting weighs 33 lbs.,


3.5 lbs. less than the weldment, and saves 100 hours of welding time per machine. Farrar also casts the wheel’s teeth, which are then roll-pinned onto the wheel. Bearly said the teeth are comparable in price to the forged steel teeth he had been sourcing from a low-cost country and provide a better, more precise fi t. T e improvement in the wheel’s


appearance is obvious, Bearly said. “I’ve brought friends and relatives


over to see the castings,” he said. “T ey look so professional and beautiful.” 


Visit www.farrarusa.com for more information on ductile iron casting.


The casting (top) saves fi ve hours of


welding per wheel com- pared to the weldment.


The wheels, shown here assembled on the axle, break up ice and snow on streets in winter-weary municipalities.


May/Jun 2012 | METAL CASTING DESIGN & PURCHASING | 49


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