detailset DESIGN
Single Casting Replaces 8 Steel Weldments
JITEN SHAH, PRODUCT DEVELOPMENT & ANALYSIS, NAPERVILLE, ILLINOIS CASTING PROFILE
Cast Component: Roller bracket mount. Process: Green sand. Material: Ductile iron. Weight: 42 lbs. Dimensions: 10 x 12 x 7 in.
F
Corner radii and fi llets reduce stress concentration for better component fatigue life in service while also improving the liquid metal fl ow into the mold.
• T e casting process works best when most of the appendages have radii as opposed to sharp edges and all the junctions (L, T, X and Y) have corner fi llets for smoother transitions.
• From a strength of materials point of view, the smoother transitions of varying cross sectional areas eliminate or reduce the stress concentra- tion eff ects.
• From a casting manufacturability standpoint, smooth transitions eliminate the risk of crack- ing and hot tearing when the metal solidifi es in the mold.
abricated structural components can be success- fully converted into one-piece castings through sound understanding of casting design and man- ufacturing, especially parting plane orientation as designated by the molding process.
Dotson Iron Castings, Mankato, Minn., and its
customer exhibited this understanding with the con- version of an eight-piece steel weldment to a single ductile iron cast roller bracket mount supporting a self-propelled spray boom used on agricul- ture equipment. By being the casting and machining source, Dotson was able to optimize the machining stock and chamfers on the part in order to improve the machining process.
18 | METAL CASTING DESIGN & PURCHASING | Sept/Oct 2015
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