detailset DESIGN
Fillets and corner radii, typical features of castings, as opposed to sharp corners and edges with weldments, add to the aesthetics, but more importantly, reduce the stress concentration and provide smooth transitions at X, Y, L, and T junctions and better fatigue performance than weldments. • A gusset provides extra stiff ness and allowed a weight reduction with the same strength.
• In many instances, gussets also assist with better heat extraction, acting as cooling fi ns during solidifi cation and cooling, resulting in a sounder casting.
Reducing the number of parts by switching to the casting process reduces weight and cost. • T e fi ve-piece steel fabrication changed to a single casting reduced costs by 37% and weight by 5%. T e conversion yielded a better product overall.
• Clearance for a wiring harness was incorporated into the design that was not feasible as a steel fabrication.
Jiten Shah is president of Product Development & Analysis (PDA) LLC (Naperville, Illinois), and a 25-year casting design and manufacturing veteran.
Jan/Feb 2017 | METAL CASTING DESIGN & PURCHASING | 15
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