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The ultimate success of the casting design depends on the communication between the designer and foundry engineers. When the foundry is properly informed of part requirements, there is usually a compromise of specifications that will allow for maximum compliance to print specifications and finish part design.
1 Standard Linear Tolerance(mm)
As-cast tolerances of angles is mainly a function of the part design and their ocation in casting. They range from +/- 1/2 degree (considered minimum) for well supported positions to +/- 2 degree where existing distortion could be expected. Inclusion of gussets and ribs normally minimizes distortion and many sections can be mechanically straightened.
3 Flatness, Strengteness and Roundness
Section Thickness
Possible Thickness Section Sink per Face of Casting
Normal
Premium
Up to 25
0.20
0.10
25 to 50
0.40
0.20
50 to 100
0.60
0.30
100 to 150
0.80
0.40
Straightening adds cost, but sometimes cannot be avoided. The actual straightening costs are often dependent on the tightness of the tolerance specified, so do not specify tighter flatness, straightness, roundness, or other requirements than you actually require. (WOTECH typically straightens parts using die sets that will be included in your tooling price. )
4 Size and Weight Range
Size and Weight. Part size and weight are the most critical factors in determining part cost because mold capacity is limited by both size and weight. The more pieces that can run on a mold, the lower the part cost. Unnecessary mass should always be removed by correct engineering practices to reduce part weight.
Items
Size
Premium
Outline Dimention
1000× 620× 380
Up to 100
Weight(kgs)
0.001-60
0.10 to 1.50
Min. Wall Thickness
0.50
5 to 10
5 Surface Roughness
80 to 120 RMS are average.
6 Hole Length
Making a good hole in a casting is dependent on the integrity of the shell. The ratio of holediameter to length is important in determining what can be offered. Blind holes must have aradius at the top and the bottom of the hole to insure that a strong core is built for castingpurposes and to insure the best possible casting.
7. When possible, parts should be designed so that a single gate can feed the part. This will generally yield more pieces per mold and reduce the pour weight per mold.
We build gate grind fixtures for virtually all parts produced that require gate grind. When possible, the part should be designed so the estment castings; Doing so will add costs. The following non-destructive tests are listed from least to greatest cost:
1. Magnetic Particle
2. Fluid Penetrant
3. X-ray
3. Flush grind
8 Heat Treatment
Heat treatments are used to control hardness, mechanical properties, corrosion resistance, and surface treatments. Unless otherwise indicated, all alloy steels are quoted with a normalize or anneal. All 300 series stainless steels and 17-4pH are quoted with a solution anneal.
9 Gaging
We perform a 100% visual inspection, However, if dimensional verification is required, a sampling plan and process control is less expensive than 100% gaging of each part. Fixed gages such as "go-no-go" are less expensive to use than gages with dial indicators. (Important: Whenever custom gages are used, there should be identical gages at WOTECH and at the customer's plant. )
10 Non-destructive Testing
All sample investment castings are non-destructively tested in order to establish first article quality. However, this is generally not required on production commercial investment castings; Doing so will add costs. The following non-destructive tests are listed from least to greatest cost:
1. Magnetic Particle
2. Fluid Penetrant
3. X-ray