Honorable Mention Valve Housing
Brillion Iron Works, Brillion, Wisconsin
Material: Ductile iron. Process: Sand. Weight: 90.12 lbs. Dimensions: 7.5 x 9 x 11 in. Converted From: Two separate cast components.
• Combining two separate castings to one led to an es- timated $1 million in savings and eliminated assembly costs, fasteners, seals and an assembly test for leakage, for this valve used in mobile hydraulics.
• A tighter core tolerance was achieved for the five- piece core assembly by assembling the core in a bucket, which also allows for less breakage in trans- port and storage.
Main Housing & Bulkheads Denison Industries, Denison, Texas
Material: A356. Process: Dry sand. Weight: 165/59/144 lbs. Dimensions: 28 x 23 x 35 in. Diameter: 23 x 6 in./32 x 6 in. Converted From: Assembly of machined and fabricated components.
• A signifi cant cost savings, more than 50%, was realized in the main housing by taking 23 welded, fabricated components and converting them to a one-piece casting.
• T e conversion also removed the necessity of a separate component for both the front and rear bulkheads, both of which were previ- ously machined from billet and mated to the separate component during assembly.
• T e three components are used for industrial-sized variable transmissions.
May/Jun 2013 | METAL CASTING DESIGN & PURCHASING | 31
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