detailset DESIGN
Achieving Best Properties in Aluminum Castings
JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE
Cast Component: Fan drive support bracket for a tractor. Process: Green sand casting. Material: Ductile iron. Weight: 44.52 lbs.
Dimensions: 15.66 x 12.65 x 7.38 in.
thicknesses, how the metal is fed into the casting, as well as molding technol- ogy, such as coatings and cooling lines.
A
chieving sound aluminum castings relies on good design that takes into consideration the rate and direction that the metal will solidify in the metal. Engineers can manipulate the design to optimize the mechanical properties that result from ideal solidifi cation. T is can be achieved through changes in wall
In aluminum, mechanical properties are directly proportional to the local cooling rate, which is driven by the section thickness. Thinner walls have better mechanical properties. • In this 165-lb. transmission housing made via nobake casting, proper wall thickness, which is a function of the overall size, casting process and desired tolerances as-cast, was chosen and optimized to make the casting manufac- turable through various design studies using casting process simulation.
• Parting and orientations were key to the success of high integrity casting production. T e interior was produced with a core, which was set into the drag (bottom) half of the mold.
18 | METAL CASTING DESIGN & PURCHASING | Sept/Oct 2016
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