Best-In-Class Lower Control Arm
Waupaca Foundry, Waupaca, Wisconsin Material: HNM 500M h gh-strength ductile ir n
NM 500M high-stri ength ductile iron..
Process: Vertical green sand molding. Weight: 25 lbs.
Dimensions: 19.3 x 15.2 x 6.8 in. Application: Automotive suspension.
• Material solutions are often sought to aid in meeting CAFE regulations by light- weighting automotive components. Coun-
terintuitive to the norm, an aluminum component was co
was converted to ductile iron to reduce weight by 25% while also reducing cost.
terintuitive to the norm, an aluminum component erted to ductile ir n to reduce weight by 25%
• To relieve a supply chain disruption involving Ford Motor Co.’s high volume CD4 platform, the carmaker worked with
aupa • Design optimization tools helped revise and verify design
oundry and Hita hi Metals to produce the high str ngth, light- weight cast iron suspension component.
Design optimization tools helped r vise and verify design concepts to produce a control arm that fit the allowable packag-
ing space, met strength and durability requirements and reduced weight. Despite a compressed schedule and expedited tooling manufacture, the production launch moved forward without any significant issues or delays.
o relie e a supply chain disruption in olving Ford Motor Co high volume CD4 platform, the carmaker worked with Waupaca Foundry and Hitachi Metals to produce the high strength, light-
May 2017 MODERN CASTING | 29
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