detailset DESIGN


Choosing between as-cast cored vs. as-cast solid features depends on the feature diameter, section thickness and feature location with respect to the parting plane.


• T e various passageways for cooling in the cylinder head have complex 3-D topogra- phy and must be interconnected, requiring multiple sand cores, assembly and careful placement into the metal mold.


• Bosses are cast solid for drilling later due to their relative size. Here, they are designed such that the risers, gates and external chills can be placed to optimize directional solidi- fi cation and desired soundness, free from shrinkage porosities.


The core print size and locations are designed to support the mechanical load of its weight as well as the hydro dynamic forces from the liquid metal during solidifi cation.


• Cored holes are required to support and locate the complex core assembly inside the mold cavity.


• Chemically bonded cores release gases during fi lling, so core venting must be considered when positioning the core prints to make sound castings.


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.


Nov/Dec 2015 | METAL CASTING DESIGN & PURCHASING | 19


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