detailset DESIGN
The cored feature placement and design should be validated for the ease of core placement, wall thickness requirements, and the risering and gating system. If it is not carefully designed, the feature may result in core breakage or rupture and poor dimensional tolerances with weight variations. • In order to allow the male-female tube attachments of the various linkages as well as all the concealed electrical and communication cabling, the interior of these rigid link castings have to be hollow and smooth, without any sharp corners for better reliability.
• Shell cores are used to hollow out the interior while at the same time providing the optimum thickness for better fl uidity of the alloy to meet structural strength requirements. With casting, it is possible to vary the wall section thickness in selective high stress areas, as opposed to fabricated tubes with uniform section thickness.
Cast features like generous fi llets and radii allow smooth transitions for aes- thetically appealing forms and shapes with better fatigue life. • It also helps design engineers reduce stress concentration, which is typically observed with fabricated sub-assemblies.
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.
May/Jun 2016 | METAL CASTING DESIGN & PURCHASING | 17
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