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details DESIGN


Manufacturing Flexibility Key to Casting Conversion JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS


CASTING PROFILE


Cast Component: Opener mount casting.


Casting Process: Green sand.


Material: 80-55-06 ductile iron. Weight: 21 lbs. Dimensions: 11.25 x 10.5 x 4.5 in.


reduced weight by 6 lbs. and allowed the customer to order in lower quantities for less inventory.


T


o convert an opener mount for an air seeder drill from a weldment to a casting, Pier Foundry & Pattern Shop, St. Paul, Minn., found a way to create one core that could be used on either side of the part to cast-in the 26 required mounting holes. T e ductile iron opener mount casting provided a 46% cost savings over the steel weldment,


Cored holes can eliminate drilling and machining.


• T e key factors driving as-cored vs. as-cast solid holes are hole diameter to thickness/depth, the pitch or inner distance between them, part- ing plane orientation and the type of molding process.


• T e series of holes could not be molded because its orientation was not perpendicular to the parting plane, so the metalcasting facility used a slab core, which could be used in diff erent pitches for diff erent mounting locations.


• Holes located parallel to the parting plane were achieved without using additional cores by incorporating them as part of the green sand mold.


22 | METAL CASTING DESIGN & PURCHASING | Sept/Oct 2012


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