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detailset DESIGN


Improvements Within Space Constraint JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS


CASTING PROFILE


Cast Component: Fan drive support bracket for a tractor. Process: Green sand casting. Material: Ductile iron. Weight: 44.52 lbs.


Dimensions: 15.66 x 12.65 x 7.38 in.


duced a cast-in feature for the added fan belt idler while fi tting within the space constraints of the engine. Ductile iron off ers the best combination of castability, strength and ductility ideal for complex structural components which otherwise are made out of multiple welded and machined steel components. High pressure green sand process is the most economical process for producing complex struc- tural iron castings in large volumes, demanding tighter dimensional control and better surface fi nish over conventional green sand casting.


A Cored hole Parting plane


tractor manufacturer’s fan drive was experiencing tensioner failures due to improper tensioner belt wrap and loading direc- tion. To eliminate this failure, it added a fan belt idler to the fan drive. Casting supplier Brillion Iron Works, Brillion, Wisconsin, was tasked with producing a new support bracket that intro-


Casting Process Aids Design


Cored pocket


Careful placement of the cored features at the parting plane during the initial design phase eliminated the need for addi- tional set-in cores, which would have adversely impacted the molding cycle time and cost. • While designing complex structural castings for green sand high pres- sure molding, the important fi rst step is to evaluate multiple parting and orientation options, before fi nalizing the optimum one.


• In addition to the feature placements to eliminate unnecessary cores, the gating and risering scheme impact the fi nal parting and orientation selec- tion. T e current state-of-the-art fi lling, solidifi cation, micro-structural, mechanical properties, soundness and residual stress predictions by com- puter simulations often are used by the design designer to fi nd optimum orientation and rigging for complex structural iron castings.


16 | METAL CASTING DESIGN & PURCHASING | Jul/Aug 2016


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