Critical Casting Design Issues --The requirements for performance, manufacturability/ castability, and cost are closely interconnected. Four casting design issues played a major role in meeting the three design imperatives

• Review the component design (cylinder and stiffening ribs) to eliminate machining steps, reduce weight, and minimize stresses.

• Design the core to maintain precise alignment for the eight bolt slots.

• Develop the mold design  to control solidification and produce the desired microstructure
  and material properties.

• Select a a tool production method to minimize tool cost with the extended production run.