details DESIGN
The as-cast support rib was designed to be stiff enough to prevent breakage during handling.
• Cast iron properties are sensitive to section thick- ness, which drives solidification and cooling rates. Very thin-walled sections may produce chilled white cast iron, which is brittle and prone to breakage. Tick sections may produce lower grade material.
• Tin to thick transitions at the X, L and T junctions need to be critically designed; otherwise junctions can create porosity, inferior mechanical properties, misruns and/or high scrap rate.
The location of an as-cast hole reduces weight without weakening the component for structural strength.
• By designing locations strategically with reference to the parting plane, it is possible to achieve as- cast cored pockets using the cope and drag pattern; no corebox tooling is required.
• By strategically designing cored features, typi- cally in low stress areas, it is possible to optimize the casting unit weight vs. other manufacturing processes such as fabrication or milling.
Pull Direction
Jiten Shah is president of Product Development & Analysis (PDA) LLC (
www.PDA-LLC.com), Naperville, Ill., and a 25-year casting design and manufacturing veteran.
Mar/Apr 2014 | METAL CASTING DESIGN & PURCHASING | 17
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