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Influence of Core Variables on Aluminum Casting Dimensions in Semi-permanent Molds

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Abstract

Castings are near-net-shape components that are almost always machined to produce the final product. Dimensional variation is driven by casting geometry, dimensional accuracy of mold and core boxes, variation in the mold and core material properties, and casting process. This work examines the shrink behavior of stepped tubular castings with varying wall thicknesses. Dimensional shrink magnitudes are related to processing factors (core type, resin content, and knock-out time) and geometric factors (section size, inner/outer diameter, location relative to parting line) using a full-factorial design of experiment. Shrink factors, a scaling number used in building tooling to obtain the correct size component, are determined as a function of the tube inner and outer diameters as well as length.

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Acknowledgements

This work was funded under by American Foundry Society (16-17#01). The authors thank the AFS (Aluminum Division) for project support, Matheus de Oliveira from Magma Foundry Technologies for solidification modeling, and Nick Hendrickson from the Michigan Tech Manufacturing and Mechanical Engineering Technology Machine Shop for measurement gages.

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Authors and Affiliations

  1. Michigan Technological University, Houghton, MI, USA

    Russell E. Stein & Paul G. Sanders

  2. Carley Foundry, Blaine, MN, USA

    Travis Bodick & Randall W. Oehrlein

Authors
  1. Russell E. Stein
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  2. Travis Bodick
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  3. Randall W. Oehrlein
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  4. Paul G. Sanders
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Correspondence to Paul G. Sanders.

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Based upon presentation given at AFS Aluminum Specialty Conference in Knoxville, TN and published in 2021 AFS Transactions.10

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Stein, R.E., Bodick, T., Oehrlein, R.W. et al. Influence of Core Variables on Aluminum Casting Dimensions in Semi-permanent Molds. Inter Metalcast 17, 604–614 (2023). https://doi.org/10.1007/s40962-022-00820-x

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