plier collabora- tion, the 842-lb. ductile iron oil pan casting for a John Deere 9-liter engine took several itera- tions and a couple of years to perfect in production. But Ol- son said that without close communication with fi rst the John Deere design engineer and, later, the John Deere Casting Center of Excel- lence (CCOE), ultimately, the converted casting might not have been delivered. T rough active participation in the design and development process, Aarrowcast was able to produce quality cast oil pans that reduced weight by 77 lbs. to meet stricter emission requirements while providing the neces- sary strength and oil capacity to accommodate a higher horse- power engine. Because of those eff orts, Aarrowcast, Shawano, Wis., has earned the 2014 AFS/ Metal Casting Design & Purchas- ing Casting of the Year award for its John Deere 9-liter engine oil pan. John Deere wanted to cut weight in
two of its large tractor engines to meet higher emissions requirements coming in Europe, and converting a stamped steel oil pan and frame casting to a single duc- tile iron casting was one way to shave off some pounds. At the same time, it was raising the engine output (by about 60 horsepower in the 9-liter engine), which imparted additional forces on the oil pan that not only holds oil but also connects the front of the tractor to its rear under the engine. When John Deere connected with
Aarrowcast to make the part, it was clear what the part needed to accom- plish, but not how it would. One of the stickiest criteria to meet was main- taining the capacity for the necessary volume of oil. “Because they wanted to reduce
weight, we ran into a lot of space restrictions,” Olson said. “We worked
MEDIA RESOURCE Using the Actable App, scan this page to watch a video point-
ing out the features of Aarrowcast’s casting. For instructions on how to use the app, go to page 1. To watch online, go to
www.metalcastingtv.com
The oil pan’s internal features are created with the aid of several interlocking cores.
Oil Pan
Cast Component: Oil pan. Casting Supplier: Aarrowcast Inc., Shawano, Wis. Material: Ductile iron. Metalcasting Process: Green sand casting. Weight: 842 lbs. Dimensions: 26 x 56 in. Application: John Deere 9-liter engine.
• T e oil pan casting design is the result of collaborative eff ort between supplier and customer to develop a casting that provided weight reduction and achieved strength requirements. T e design team utilized a combination of fi nite ele- ment analysis and solidifi cation simulation to achieve the desired outputs.
• T is casting design was able to combine a frame casting, two fabricated brackets and a stamped steel oil pan into one ductile iron casting. T e customer received a weight reduction of 77lbs. that supported an increase of 60 horsepower to the engine.
• Because of the compact design of the oil pan casting the package allowed for a lower engine position in the tractor chassis and eliminate a 2 degree angle of the engine. T e volume of oil was increased over the steel stamping.
May/Jun 2014 | METAL CASTING DESIGN & PURCHASING | 19
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