Ductile
Iron Castings to Reduce Cost
and Improve Performance |
The
Challenges -- Originally
designed as a welded assembly of six steel pieces, the housing component
Had significant fabrication
costs in the fixturing and welding of the assembly
Required extensive machining for
eight bolt slots, three internal bearing pockets, and four rib stiffeners
Was not optimized for strength
or weight savings
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Benefits of Using a Ductile Iron Casting -- The
casting design study showed that the housing cost could be reduced by 15% (compared to the
original assembly design) by using ductile iron casting in sand molds. This cost reduction
was achieved by:
- Improved near-net shape which eliminated cutting, assembly, and
welding steps and
reduced machining operations.
Conversion to a casting optimized
the weight and strength of the component with more robust cross-sections in stressed
sections and reduced weight in unstressed volumes.
Redesign of the reinforcement ribs
provided for easier tool access during bolting of the housing to the frame.
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