From May 2016 MODERN CASTING
Best-In-Class
Walker Casting
Monarch Industries Ltd., Winnipeg, Manitoba, Canada
Material: Ductile iron.
Process: Green sand.
Weight: 40.7 lbs.
Dimensions: 14.54 x 31.4 x 4.24 in.
Application: Main mounting structure for tillage equipment wheels
Converted from a steel weldment, the castings provided an average cost reduction of 30%, according to the customer. Working with a machined casting, as opposed to a welded fabrication, provided a part with tighter tolerances without any welding-induced distortion. The casting was designed to eliminate the need for left-hand and right-hand versions of the parts.
Best-In-Class
9RX 4-TRAX Drive Housing
John Deere Waterloo Foundry, Waterloo, Iowa
Material: 65-45-12 ductile iron.
Process: Green sand.
Weigh1: 1,359 lbs.
Dimensions: 47 x 51 x 34 in.
Application: Contains driveline components for each track in a tractor.
The cast component serves as a critical component to a new tractor John Deere entered into the agriculture market. During product development, 3D printed molds were used to shave eight weeks of time for each build.
Honorable Mention
Grill Set
Goldens' Foundry & Machine Co., Columbus, Georgia
Material: Cast iron.
Process: Green sand.
Weight: 334 lbs.
Dimensions: 30.25 x 22.5 x 29.75 in.
Application: Cooking and grilling.
This grill set offers an alternative to the ceramic kamado grills for outdoor cooking. Cast iron provides greater strength and durability than ceramic and is an optimal material for cooking. Designed to allow for air insulation between the heat source and the exterior of the cooker, the cast iron grill set extends the heat cycle life beyond the ceramic designs.
Honorable Mention
Sprocket
Aarrowcast Inc., Shawano, Wisconsin Material: 100-70-03 ductile iron.
Process: Green sand.
Weight: 768.2 lbs.
Dimensions: 41.5 in. x 19.76 in.
Application: Drive sprocket for rubber track system.
Initially designed as a 39-piece steel fabrication, the cast sprocket transfers power provided by the lower powertrain to drive the rubber track that is engaged to propel the tractor. Casting benefits included a more concentric part, better cosmetics and supply chain improvements due to fewer processing steps.
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