detailset DESIGN
Unique Casting Features Lead to Reduced Weight, Costs
JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE
Cast Component: Frame mounting bracket.
Process: Green sand. Material: 65-45-12 ductile iron.
Weight: 9.9 lbs. Dimensions: 8 x 4 x 6.5 in
The parting plan followed the contour, thereby eliminating a core. • Careful feature placements with respect to the pattern plane allows the elimination of cored features.
• Cores add dimensional variability and an additional operation and cost element.
created a no-core design, which helped keep production costs lower, and devised a way to incorporate an additional feature that provided clearance for a wiring har- ness. T e ductile iron casting also weighed 5% less than the steel weldment.
M
etalcaster Advanced Cast Products (Meadville, Pennsylvania) achieved a 37% cost reduction on a frame bracket for a heavy truck application by redesigning the bracket and optimizing it for green sand casting. Originally a steel fabrication, the bracket supports the split shaft power take-off . Advanced Cast Products
Deciding between a cored or drilled and machined out hole depend on the hole dimensions, diameter, thickness and the location of certain features. • Some holes were drilled due to their relative size and location from the parting plane.
• T e larger hole was cast solid and machined out because it’s location, being perpendicular to the parting plane, made it not feasible to place a core.
14 | METAL CASTING DESIGN & PURCHASING | Jan/Feb 2017
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