FOR PRACTICAL CASTING DESIGN


TECH TRENDS


A customer’s quality and lead-time issues were solved through the use of new technology for stress analysis and mold-making.


A SHANNON WETZEL, MANAGING EDITOR


ll 10 castings in the initial trial run showed the crack. It was at the corner of a rib, sometimes in sev- eral points. Filling and solidifi cation modeling had indicated no issues. T e manufacturere of industry air compressors had a case to solve, and time was running short. T e part was a 442-lb. gray iron gear case cover housing used in air compressors located in free- standing boxes at worksites to generate industrial air and power. It was a prototype casting to go into


production in late 2016, and further development of the air compressor assembly hinged on its successful and timely manufacture. Dalton Foundry, which is a divi-


sion of Neenah Enterprises Inc., had built production intent metal proto- type tooling for the part after casting process modeling showed no fi lling or solidifi cation problems with the


Casting this gear case housing for a large commercial compressor assembly did not prove to be easy. An early design resulted in cracks in each of the fi rst 10 castings produced during the trial run.


Sept/Oct 2015 | METAL CASTING DESIGN & PURCHASING | 25


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