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Cores' Role in Casting Design |
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Page 4 of 4 The component integration was made possible with seven individual shell cores that were built together to form a one-piece assembly. The assembly process required that proper tolerances were held to meet near-net shape requirements. The final core assembly was stacked on two previously-assembled cores and needed to hold a height tolerance in order to kiss against the mold surface tight enough to ensure the printout of the cored holes did not distort.
This complex use of cores helped reduce the customer’s inventory, avoid extra machining costs and eliminate five hydraulic connections, which improved safety and quality.
 Fig. 2. The core design for this intake manifold incorporated a one-piece core rather than an assembly.
“Typically, customers don’t know how the cores are being used in a part,” Gwyn said. “Be aware that cores exist. Once you start thinking about the geometry of the part, start talking with the metalcasting facility’s engineer about the capabilities of cores.” Metalcastingdesign.com
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