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What key points should be considered in the structural design of castings?
2020-05-30
In addition to meeting the requirements of the machine equipment itself and the machinability requirements, the design of casting structure should also comply with the requirements of the casting process. The structural design of the casting should pay attention to the following points:
1. It should be easy to manufacture the model, core box, and molding:
1) The shape of the casting should strive to be simple to facilitate mold removal, and the casting parting surface should be as flat as possible and minimal in number;
2) The internal cavity of the casting should strive to avoid or minimize the use of cores during casting. When cores are used, their support, fixation, venting, and sand removal should be convenient, and sufficient process holes should be provided if necessary;
3) For the inner and outer surfaces of the casting and reinforcing ribs, a certain draft angle should be set in the mold removal direction;
4) The boss parts on the casting should not differ too much from the main body of the casting, preferably having the same height. Several bosses close to each other on the same surface should preferably be connected into an integral raised part.
2. Reduce the tendency to produce casting defects:
1) The wall thickness of the casting should strive to be uniform to prevent shrinkage cavities and hot cracks. When ensuring directional solidification, the wall thickness should vary in one direction as much as possible. When ensuring simultaneous solidification, the wall thickness should be as uniform as possible;
2) The connection between walls should strictly avoid sharp corners and metal accumulation. The transition between thick and thin walls should be gradual to prevent sudden changes, which can cause hot spots and stress concentration, leading to hot cracks and shrinkage porosity;
3) Local thick sections of the casting should be hollowed out or have cast holes as much as possible, and appropriately reinforced with ribs;
4) Cast holes on flat walls of the casting should be reinforced with raised edges to reduce wall thickness;
5) The casting structure should allow unobstructed shrinkage during cooling as much as possible;
6) Large horizontal surfaces inside the casting should be avoided as much as possible;
7) Large interlayer cavities such as water channels and air channels inside the casting should have several connecting pillars.
3. Ensure the casting has good formability and control the minimum wall thickness of the casting not to be lower than the allowable value.
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2026-09-05
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