Casting in features is often economical, but sometimes drilling them later is more cost effi cient. In highly automated molding processes, eliminating cores will increase cycle times and provide better dimensional accuracy. On this auxiliary drive casting, deep pockets are cored with higher draft angles, but mounting holes on the vertical surface are cast-solid and drilled later.


In lost foam, cast-in hole placement depends on the diameter relative to the adjoining wall section thickness, irrespec- tive of orientation, so design engineers are not limited by location and orienta- tion. The reductions in strength and stiff- ness caused by cored holes versus a solid casting in this towing eye bracket are recovered with localized raised bosses or beaded holes.


In this graphite diecast handheld translator, the gasket groove area was designed to be machined as opposed to as-cast due to the assembly’s tight toler- ance requirements and desired water tightness.


Sept/Oct 2014 | METAL CASTING DESIGN & PURCHASING | 31


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