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details DESIGN


Feature Location Key in Casting Quality, Cost


JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS (NAPERVILLE, ILLINOIS) CASTING PROFILE


Cast Component: Exhaust base oil cooler engine manifold.


Process: Green sand molding. Material: Class 30 gray iron. Weight: 30.35 lbs. Dimensions: 20 x 7 x 9 in.


I


f proper key design options of parting lines and orientations are not evalu- ated in depth during the product conceptual stage, a design could inherit manufacturability-related issues resulting in poor quality, consistency and higher scrap. For an exhaust base oil cooler engine manifold for heavy truck/ mining, the initial part design was proving to be problematic for the volumes


and quality required. Supply fell behind, and the scrap rate was too high. T e ma- chine shop and its customer collaborated with a new supplier—Prospect Foundry (Minneapolis)—to redesign the part by rotating the parting plane 90 degrees to eliminate a core. T is resulted in 18% cost savings, lead time reduction from eight weeks to fi ve weeks, and 5% reduction in external scrap.


Upfront evaluation of the right part orientation and parting plane is key to the successful development of a complex casting and can only be achieved through intense collaboration among the team members. • T e parting plane as shown allowed to make this complex cored casting by eliminating one core.


• Green sand molding is an eff ective method when the num- ber of cores required are optimized by careful parting plane determination. However, the process requires generous draft angles and smooth fi llet and radii for capturing casting details accurately and consistently.


• Collaboration should happen among various teams, includ- ing the OEM design team, foundry and machining shop.


16 | METAL CASTING DESIGN & PURCHASING | May/Jun 2017


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