May 27, 2009

Basic Rules for Modeling/Designing Casting Parts

A Sand Casting Part

Castings should be carefully designed to take full advantage of the economy inherent in the casting process without sacrificing the quality of the finished part. The designer should consider ease of casting and machining as well as the shape required to allow the part to function properly. Casting design is often influenced by the methods, size of equipment, etc., at the foundry where the castings are to be made, as well as by the machines and methods available for the machining operations.

The most important rules for good casting design can be stated briefly:
  • Use relatively thin sections enlarged where necessary to hold other parts, permit fastening, etc.
  • Provide bosses or machining pads wherever flat surfaces are to be machined.
  • Reinforce the edges of the piece by providing an enlarged section.
  • Provide bosses around holes or openings in the part to reinforce the part and thus make up for the metal lost due to the hold.
  • Strengthen and stiffen light sections with ribs.
  • Blend thick and thin sections together gradually to eliminate cooling difficulties.
  • Always provide generous fillets where two surfaces come together, being careful to eliminate all sharp corners.
  • Use simple curves which are easy for the patternmaker to produce

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