Casting Design Improvement

Due to advantage of possibilities of optimizing weight and cost of products

, casting, be it aluminium casting or other metal castings, is the process of choice for complex design products. It provides advantage of being able to produce highly complex functional shapes quickly and easily.

But the advantages of casting products depend on the quality of casting design. Once the design is finalized, the production of casting product is very cost efficient. Weight distribution can be optimized based on design of the product and material can be distributed based on load strength required for the sections of the product.

A mentioned above, the optimal casting design for producing aluminium and other metal casting products is necessary. There are two main goals in casting design:

1.Functional requirements of the final product and

2.Constraints which relate to the

a.form (shape, size, surface finish, precision, etc.) and

b.processing (parting line, draft, section thickness, etc.) requirements that constrain the geometry that can be selected.

The above two is used to define the problem of casting and an initial design is created. Thereafter, in a iterative step, the design is continuously evaluated and modified iteratively until an acceptable design is achieved. The iterative redesign is guided by the design information, insight, and understanding developed in the evaluation step. The final objective of the iterative design process is to satisfy all functional requirements and constraints. In cases where it is not possible, the problem is redefined after tweaking the functional requirement and constraints in light of knowledge acquired during the iterative process.

Avoid excessive design iterations

Excessive design iterations should be avoided as they can adversely impact the casting design. The design iterations incur cost and time and make the casted product costlier. The design iterations, especially those performed late in the process, can lead to suboptimal design. This may result in a casting that falls short of cost, weight, and performance targets. Such designs give casting a bad reputation and are a disappointment to all concerned.

Challenges with light alloy castings like aluminium casting

The low density of aluminum makes riser design more difficult than for most other heavy metals. In addition, its low heat-released-per-unit-volume ratio and high conductivity makes the gating design a real problem in terms of sequential solidification requirements.

The pouring cup should be kept full during pouring of the metal to prevent vortex formation in the sprue. A pouring basin can be used to ease the filling of the mold and also to minimize the possibility of air and oxide entrance into the mold cavity. The filling of the pouring basin should be done as far from the sprue as possible.

Refer to http://www.pacriment.com/ for all casting products including aluminium casting and metal castings.

by: pacriment

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