search.noResults

search.searching

note.createNoteMessage

search.noResults

search.searching

orderForm.title

orderForm.productCode
orderForm.description
orderForm.quantity
orderForm.itemPrice
orderForm.price
orderForm.totalPrice
orderForm.deliveryDetails.billingAddress
orderForm.deliveryDetails.deliveryAddress
orderForm.noItems
at the workstation. Critical to this step was the quality of the sand. Knowing this, TEI turned to AFS Corporate Member Hoosier Pattern (Decatur, Indiana) to produce the two 3-D printed molds. “It was vital that we had really good sand that could be cleaned easily,” Johnson said. After cleaning, machining was


another challenge. “Tere were only three areas to


machine, but the part isn’t easy to hold or access,” Johnson said. “While were working on the mold design and casting the part, in parallel we were designing and machining a fixture.” TEI used simulation to map out


the entire manufacturing process of the swingarm, including machining. Te prototype mapped out the whole machining operation in a virtual simu- lation that simulated the cutting tools, fixtures, and the motions of the pallets. “Everything is simulated because


you don’t want to have a mess up on a job like this,” Johnson said. Te simulation paid off. Te two molds both produced good parts, cleaning was successful, and machin- ing operations were completed with- out a hitch. After CT scanning, white light scanning, x-ray inspection, and dimensional checks before and after heat treating, the swing arm was ready for the customer within the three- week deadline. “One of the reasons this has been


such a strong collaboration is TEI is an early adopter and strategic user of technology, particularly in simulation technology,” Bastian said. “Te casting coming out right the first time was pretty phenomenal.” Te success of the cast swing arm will help Autodesk further make a case for


The swing arm was designed for the Lightning LS-218 motorcycle.


applying generative design to not just metal printing but also metalcasting. “Metal printing likes to show


all these exotic shapes that can be produced, but we want to demonstrate casting is a technology that is quite well suited to those shapes, particularly when you are making something larger than a bread box,” Bastian said. “Met- alcasting offers hundreds of materials to choose from compared to metal printing, and the manufacturing base is mature.” Kahaian agrees and is excited for


the future of metalcasting as the adop- tion of additive manufacturing in the industry speeds up.


“3-D printed sand is a cheap medium to print in, and it’s using the same materials we have been using for hundreds of years,” he said. “It’s unlimited in size. It is the future, and realistically, there are no boundaries.” Designs like the swing arm are great


showpieces, but Johnson believes the impact can go past the exhibit floor. “You might not see parts like the swing arm on a mass-produced vehicle, but you could apply the same approach of optimized design,” he said. “Te part may only look subtly different but it still can be optimized with the appropriate constraints of conventional technology.”


BACKGROUND ON THE CASTING OF THE YEAR COMPETITION


Te annual Casting of the Year competition is sponsored by the American Foundry Society and Metal Casting Design & Purchasing magazine and recognizes excellence in casting design. Te competition is open to all North American metalcasters and designers/end-users of metal castings. Castings are accepted in all metals, casting process, end-use applications and sizes.


MEDIA RESOURCE To see a photo gallery of the


excellent casting designs honored in this year’s competition, visit www.moderncasting.com.


Independent judges evaluate each entry on: • Benefits delivered to the casting customer. • The use of the casting process’ unique capabilities. • Contribution to growth and expansion of the casting market.


May 2018 MODERN CASTING | 31


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76