detailset DESIGN
Flexibility i n gating and riser placement allows liquid metal to fl ow into intricate shapes with high defi nition, excellent surface fi nish, as-cast cored holes, pockets and thin wall features.
• T in walls and castable cored holes and pockets replace expensive secondary machining operations.
As-cast cored features eliminated secondary machining.
• Low thermal gradients due to a pre-heated ceramic shell in the investment casting process enables the casting of thin walled confi gurations with intricate cored holes. T e smooth fi nish of the wax pattern and slurry-based fi ne mold/ceramic shell substrate material results in an excellent surface fi nish.
Principle parting plane
New design consists of three castings.
In order to consolidate multiple pieces, complex features are broken into simple shapes based on the parting and orientation of the wax die.
• T e key driver for this design was part consolidation by incorporat- ing various sub-components and features into a three-piece casting, which is near-net shaped and lighter than the fabricated route.
• Investment casing off ers fl exibility with multiple parting planes and their orientations thereby allowing any complex features to be cast along with the main shape.
Previous assembly had 35 pieces.
• In investment casting, it is common to glue or assemble multiple wax sub-components to facilitate complex shapes which are other- wise not possible with one parting plane. At times, loose pieces are used to accommodate the stripping of the wax shapes with re-en- trant angles. T e process allows the placement of features away from the parting plane in any random orientation.
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.
Mar/Apr 2017 | METAL CASTING DESIGN & PURCHASING | 15
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