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Chapter 12
Design Considerations
Developed over many years
Established though practical experience Analytical methods Process modeling CAD Manufacturing techniques
Machining allowance
Residual stresses
Fig : Suggested design modifications to avoid defects in castings. Note that sharp corners are avoided to reduce stress concentrations.
Fig : Examples of designs showing the importance of maintaining uniform cross-sections in castings to avoid hot spots and shrinkage cavities
Chills
Fig : The use of metal padding (chills) to increase the rate of cooling in thick regions in a casting to avoid shrinkage cavities.
Aluminum alloys
Magnesium alloys Yellow Brass Phosphor bronze Aluminum bronze High-manganese steel
1.3
1.3 1.3 1.6 1.0 1.6 2.1 2.6
Parting Line
Fig : Redesign of a casting by making the parting line straight to avoid defects.
Examples of undesirable and desirable design practices for die-cast parts. Note that section-thickness uniformity is maintained throughout the part.
Copper-based alloys
Zinc-based alloys High-temperature alloys
THE END