An Example in Steel  Casting  --  Lever Arm in the BMW Engine Valve Train

Manufacturing Challenges

Two production options were considered for the production of the lever arm --  casting and forging.
  • The production requirement  is 2.5 million lever arms per year with requirements for precision tolerances, controlled cost, and minimal machining. (The steel alloy is very hard with limited machinability.) 
  • With those requirements casting is the production method of choice.   
    • Casting produces a near-net shape component with the minimal amount of additional machining. 

Hitchiner Manufacturing produces 10,000-12,000 finished lever arm assemblies every day.

The challenge in manufacturing this component was to select the best metal alloy and  optimize the casting design to meet the performance and production targets:

-- Achieving high strength, wear resistant alloy performance.
-- Meeting the required dimensional tolerances for fit and function.
-- Producing a high quality, flaw free part on-time and at-cost.


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