You have designed a 2 pound gearbox housing casting Material is 356 Aluminum. Qu
ID: 1843803 • Letter: Y
Question
You have designed a 2 pound gearbox housing casting
Material is 356 Aluminum.
Quantities are 50,000/year
Wall thicknesses vary between .2 and .25 inches
The overall part size is 6 x 4 x 3 inches
An alligator skin decorative pattern is desired on the top surface
The part must seal oil on the inside
1) Explain in detail the strengths/weaknesses of sand casting for each of these specifications
2) Explain in detail the strengths/weaknesses of investment casting for each of these specifications
3) Explain in detail the strengths/weaknesses of die casting for each of these specifications
4) Explain in detail the strengths/weaknesses of gravity filled permanent mold casting for each of these specifications
Explanation / Answer
1. Sand casting: Aluminum is the material to be cast, so comparately ease of melting and pouring is involved in case of sand blasting. Can be prefered for this advanage only. Disadvantages are: 1. Induced porosity due to ability of aluminum to form oxides in contact with atmosphere. 2. Induced defect due to high heat conductivity of Al is very high and solidification problems can not be avoided in sand casting.
2. Investment casting: Advantage: Highly precise parts can be made by this method. Involves high precision casting and high value materials. Disadvantage: In this case of Al casting, investment casting willl not be prefered as it may involve high set up cast and also the production rate is very low with investment casting. Our requirement is quite high so it is definetly not an option.
3. Die casting: Die casting can be used to cast low melting point alloys and aluminum is one of the kind. Also the induced problem of porosity and scale formation due to oxides can be removed using die casting process. The production rate and sealing oil capacity both can be acheived with die casting. Disadvantage: High cost compared to sand casting options, but can be compromised with the part quality.
4. Gravity feed mold casting: Strength: Breakable molds and low set up and tooling costs favors this but disadvanages of casting defects are more prone to avoid this casting method.
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