details DESIGN
Collaboration on Product Launch Yields 50% Weight Reduction
JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE
Cast Component: Main transmission housing for heavy industries.
Material: A356-T6. Weight: 165 lbs. Dimensions: 28 x 23 x 35 in.
Process: Nobake sand casting.
Application: Heavy industry/ energy market.
cost savings and reducing time to market. T e main housing structure, previ- ously a 23-piece welded fabrication, was redesigned as a one-piece casting for a 50% cost savings. T e cast front and rear bulkheads originally were machined from billet.
A
Smooth solidifi cation transitions are achieved using generous fi llets and radii for the appendages.
• Casting process modeling is an eff ective tool to validate the casting design and process to ensure the desired quality is predicted before releasing the fi nal design and building an expensive tool.
• In this local solidifi cation time profi le of a casting, notice the hot spot inside the pocket area.
• In this temperature profi le of a pocket core during solidifi cation, notice the super-heated core sand in the pocket, with temperatures as high as 2,550 F (1,400C).
casting end-user was midway through its design for manufac- turing analysis for a new product launch when it approached metalcasting facility Denison Industries, Denison, Texas, for input. Working together, the customer and Denison reduced the 27-piece structure to a three-piece unit, resulting in signifi cant
16 | METAL CASTING DESIGN & PURCHASING | Jan/Feb 2014
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