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details DESIGN


Incorporating Fasteners Saves Four Hours Assembly Time


JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE


Cast Component: ProTec Series 30 Cast Subframe Process: Green sand Material: Ductile iron Weight: 225 lbs.


Dimensions: 27.7 x 32.9 x 20.8 in. Application: Military


components and 136 fasteners, all of which were consolidated into a one-piece casting design, cutting the weight from 311 lbs. to 225 lbs. A carefully designed and engineered cast component can incorporate fasten- ers as a part of the design and assist manufacturing engineers with tremendous time and cost savings. T e key to success is using the knowledge of the dimen- sional tolerances of the casting processes to line up features at the locations they are required to be mounted.


M


eritor Design, Troy, Mich., avoided four hours of assembly time and reduced the weight of a military vehicle subframe by redesigning a weldment as a ductile iron casting. T e subframe carries the suspension cross-over assembly and integrates to the vehicle frame rail. T e original fabrication consisted of 79


Smooth transitions provide better aesthetics and lower stress concentration.


• Casting allows for smooth transitions from thick to thin sections and from one region to another functional region by incorporating complex blends, generous radii and fi llets.


• Appendages with radii, as opposed to sharp edges at junctions and corner fi llets, lead to smoother transitions. Smoother transitions of varying cross sectional areas eliminate or reduce the stress concentration eff ects and result in better component fatigue life in service.


16 | METAL CASTING DESIGN & PURCHASING | Jul/Aug 2014


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