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PRINCIPLE NO. 9-

COMMUNICATE WITH THE FOUNDRY

It may seem an admission of defeat to again suggest, after all the casting design principles described previously, that the designer should confer with the foundryman before finalizing his plans. However, this suggestion constitutes the last principle of designing castings in Ductile Iron.

No designer will be an expert foundryman after having read the brief fundamentals of the casting process and the particulars pertaining to Ductile Iron. Following these fundamentals will hopefully assist in avoiding major design errors. Deciding on fine details of potentially large significance in economy and

performance requires a more profound understanding of both the casting process and the particular foundry involved.

The best time to meet with the foundryman is during the design of the "raw" or "ideal" part. The foundry will be anxious to cooperate in determining whether or not any modifications are needed to facilitate casting production. The suggested modifications will not necessarily be acceptable to the designer, but both sides will most certainly gain from the communication. The foundryman will also be pleased to show you his foundry in operation, the capabilities of his molding line and his core making facilities. You may be able to see some good examples of castings similar to your design.

COURTESY: PONTIAC MOTOR DIVISION, GENERAL MOTOR CORP.

Redesigned automobile crankshaft, used in the Pontiac 2.5 liter L4 engine. According to the designers, the new nodular (ductile) iron casting is 10 lbs. or 23% lighter than the one it replaced. This was accomplished without sacrificing the crankshaft's durability or integrity.

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