details DESIGN
Part Consolidation Saves Customer Big Money
JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE
Cast Component: Valve housing. Process: Green sand. Material: Ductile iron. Weight: 90.12 lbs. Dimensions: 7.5 x 9 x 11 in.
Works, Brillion, Wis., allowed the team to adjust the design of its two-piece as- sembly based on form, fi t and functionality to save an estimated $1 million. T e original two-piece assembly was redesigned as a single ductile iron sand
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casting, produced with a fi ve-core assembly. T is eliminated the cost for assembly, fasteners, seals and assembly test for leakage. It also allowed for more fl exibility in machining tooling and improved hydrostatic braking and operation of the fl uid power system.
Consolidating cores into a core assembly improves dimensional tolerances and cycle time.
• Cores are necessary to produce internal features as well as features not accessible from the parting line, but every cored feature adds variability due to the clearance required between the core print on the core and the mating core print on the pattern.
• By pre-assembling fi ve individual cores, the casting facility can visually inspect and validate with a gauging fi xture before placing the core pack- age into the mold. T is change pro- duces castings with tighter tolerances and fewer dimensional variations.
• Properly interlocked cores in an as- sembly prevent the cores from fl oat- ing in the mold due to the buoyancy of the liquid metal during fi lling and the early stages of solidifi cation.
• Core assembly improves cycle time because only one core setup opera- tion is required.
orking with a sound casting knowledge base, either at your company or your casting supplier, can yield signifi cant dividends. In the case of a valve housing for a hydraulic fl uid power system for a mobile hydraulics end-user, collaboration between the customer and its casting supplier, Brillion Iron
16 | METAL CASTING DESIGN & PURCHASING | Jan/Feb 2015
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