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detailset DESIGN


Radii


Generous fi llet, radii and transitions aid castability and help reduce high stress concentration spots. • Castability features such as radii, fi llets and blends not only assist casting engineers with better streamlined fl ow passages and soundness, they also aid structural engineers by reducing or eliminating high stress concentration spots, thereby improving the overall fatigue life of the components in service.


Smooth blend


Fillet


By consolidating multiple sub-components, which are otherwise welded or fastened, the overall cost, lead time and fi nal product performance improvements are achieved. • Casting manufacturing made it possible to incorporate the tensioner idler feature into the support bracket, an advantage over fabrication, machining and forging processes.


• Occasionally, the additional machining and assembling op- erations are eliminated by part consolidation design.


Jiten Shah is president of Product Development & Analysis (PDA) LLC (www.pda-llc.com), Naperville, Illinois, and a 25-year casting design and manufacturing veteran.


Jul/Aug 2016 | METAL CASTING DESIGN & PURCHASING | 17


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