detailset DESIGN
Sand and Metal Combine for Optimal Molding in Cylinder Head
JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE
Cast Component: 6.7L cylinder head for Ford diesel internal combustion engine.
Process: Permanent Mold. Material: 356 aluminum. Weight: 41 lbs. (18.6 kg).
Dimensions: 21 x 10.3 x 4.9 in. (534 x 262 x 125 mm).
lation. Producing the part in the gravity-fed permanent mold process allowed for higher cooling rates and better mechanical properties compared to sand casting. Inorganic cores, which emit fewer emissions during casting, were used to make the internal passageways.
S
imultaneous product and process engineering between the customer and casting supplier Nemak, Nuevo Leon, Mexico, meant a product launch in two years instead of fi ve for a cylinder head for a Ford diesel internal combustion engine. T e casting is made in a high temperature resistant aluminum alloy and features cast-in positive crankcase venti-
In semi-permanent mold casting, features demanding higher performance are placed on the outside.
• T e semi-permanent mold casting process combines complex internal passageways (made using sand cores) with high mechanical properties.
• Locating features needing higher performance where they will be in contact with the metal mold will yield higher cooling rates and lower dendrite arm spacing, ultimately pro- viding higher mechanical properties.
• Filling and solidifi cation simulation shows the eff ect of a metal mold and the sand cores on the cooling rate of a casting.
18 | METAL CASTING DESIGN & PURCHASING | Nov/Dec 2015
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