Efficient Wall Thickness Analysis Methods for Optimal Design of Casting Parts

Wall thickness is an important parameter for casting design. Thin wall sections cause breakage of parts during manufacturing or during usage of the part. Thick wall sections cause problems in castings and increase weight, needs more material thus increasing the cost. Optimal wall thickness is also important for adequate and sufficient strength of parts. The current process of wall thickness measurement involves taking sections of the design along standard axis and then measuring those sections using tools available in Computer Aided Design (CAD) Software. Designers use these methods to measure wall thickness. It takes couple of weeks time to analyze a complete casting for power train parts. Moreover, the process is not accurate and error prone. Most of these errors may be detected during simulation and analysis phase. This phase is a complex and time consuming process. Also it requires specialized knowledge to use these softwares. In this paper, we describe an easy and efficient process related to wall thickness check for power train design, where design checks are performed in an automated fashion by the designer. This helps to correct many of the defects arising out of the wall thickness of the model. By providing this process right at the design stage, valuable time and effort is saved. Also high quality of the part guaranteed right at the design stage.