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Honorable Mention Differential Case


Waupaca Foundry Plant 4, Marinette, Wisconsin


Material: Ductile iron. Process: Green sand casting. Weight: 13.5 lbs. Dimensions: 7.5 x 9.75 x 9.75 in. Application: Driveline for automotive-light truck.


• T e customer wanted an optimized helical advanced diff erential case designed in a short timefr


e custo t timeframe. Normally a core would be used to


cast the desired internal features, but the customer wanted win- dows in the side of the casting for oil fl ow, which would have been cost prohibitive.


• T rough collaboration, Waupaca and the customer moved parting lines, changed surface draft and altered machined stock to incor- porate a wraparound core that reduced the weight of the casting and minimized the amount of material to be machined off . • Computer modeling and communication between Waupaca and the customer r porosit


was remo casting design also lo


mer resulted in a more robust design that eliminated


osity in some areas and repositioned porosity in other areas so it emoved during machining or placed in safe locations. T e iterative asting design also lowered machining cycle time, further reducing total manufacturing cost for the customer.


Accessories Plate Tooling & Equipment International, Livonia, Michigan


Process: Low pressure sand casting. Weight: 34 lbs. (15.4 kg).


Material: A356.


Dimensions: 31 x 14 x 6 in. (800 x 350 x 150 mm). Application: Integrates inter accessories in power generators.


• T e accessories plate casting is the largest casting in the Ecomotors opposed piston cylinder engine. It integrates the internal cooling and air management of the engine and provides mounting surfaces and pre- cise geometry for the fuel system as well as the external accessory drives.


• T e prototype component was produced in nine days, from start of engineering to fi rst casting, with no tooling investment. ccor


• According to the customer, TEI’s turnkey process eliminated the need for costly tooling during develop-


ates internal cooling, air, fuel and


eliminated the need for costly tooling during de ment cycles and costs wles and costs were competitive with Asian and Indian sources with a much shorter lead time. ■


May/Jun 2015 | METAL CASTING DESIGN & PURCHASING | 29


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