Aluminium Casting Of Upper Body

Aluminium Casting Of Upper Body

The Upper Body is a precision aluminium casting that forms the top half of a split housing or enclosure. It provides structural rigidity, alignment features for mating parts, protection for internal mechanisms/fluids, and interfaces for mounting, sealing, and service access. Designed for robust performance with low mass, it’s optimized for manufacturability (drafts, uniform wall thickness, fillets) and durability (heat-treatable alloys, corrosion protection

  • Lightweight & rigid
  • Sealing-ready
  • Alignment & assembly
  • Thermal & corrosion resistant
  • Machining allowances built-in
  • NDT capable

1. Assemblies

  • Lower Body / Base: Forms the closed housing when fastened together.

  • Sealing elements: O-rings, gaskets (NBR/FKM/PTFE), sealant (where applicable).

  • Fasteners: Socket head cap screws or studs/nuts; thread inserts (helicoils/keenserts) for durability.

  • Guidance & alignment: Dowel pins, locating shoulders, pilot recesses.

  • Internals (as applicable): Bearings/bushes, shafts, impellers, valve trim, PCB/heatsinks, filters, baffles.

  • Ports & interfaces: Tapped bosses, flanges, cable glands, breathers/vents.

2. Design & Drawing Guidance

  • Provide primary datums on robust, machined features (e.g., base pad = Datum A; side pad = Datum B; bore = Datum C).

  • Call out draft, radii, and machining allowances on a separate “non-dimensional” view or note block.

  • Keep walls uniform; use ribs/gussets instead of thick masses (target 30–60% of wall for rib thickness).

  • Avoid blind pockets; enable tool pull and core access.

  • Add O-ring grooves per ISO 3601 / manufacturer data (specify cross-section, squeeze, gland volume).

  • Use GD&T for function: flatness/parallelism on sealing faces (e.g., 0.05 mm over 150 mm), position on dowel holes (e.g., ⌀0.10 at MMC to datums A|B), perpendicularity of bores to A.

  • Indicate porosity-free zones under sealing lands; apply local RT acceptance.

  • Provide CMM inspection plan and sampling (e.g., PPAP if automotive).

  • Specify heat treatment and impregnation (if any) in the notes.

  • Add coating stack: pretreat → primer → topcoat, with thicknesses and color code