Designing cast shapes.

Fillets
Intersecting surfaces forming junctions of metal thickness are properly joined with fillets in order
to avoid high stress concentrations in the diecastings, and to control and facilitate maintenance
of otherwise squared edges in the casting die. Fillets projected in a direction normal to the
parting plane require a draft angle, but the amount is always governed by the draft of the
intersecting surfaces. Draft in corners or fillets projecting in a direction normal to the parting
plane have approximately 1.5 the amount of draft of the intersecting walls.
In the sketches given below, consideration has been given to the stresses of use and the
stresses induced in the diecastings by the process, as well as to die manufacturing and
maintenance costs. The suggestions apply to fillets in corners which are projected normal to the
parting plane in diecastings of moderate depth. Shallow castings may have much smaller fillets,
while deep pockets and other inside corners may have larger fillets. Sharply squared corners
with considerable length projecting in a direction normal to the parting plane may cause spalled
edges in withdrawing the diecastings from the die.
It should be noted that the recommendations on this page represent normal production practice
at the most economical level. Sharp inside surface junctions, acute angle corner conditions and
delicate, deep and closely spaced ribs should only be specified where and when necessary
since additional costs may be involved.

Recommended


Less Desirable



Not Recommended


Ribs
Ribs are used to increase the stiffness of or add strength to a diecasting. They are able to assist
in the manufacture of sound castings. Ribs are sometimes misused and can be a detriment if
working stresses are concentrated by their use, or if stresses at the edges of the ribs are high.

Recommended


NOT Recommended


External Corners
Sharply squared corners may be used in many locations if the die construction permits them.
This type of corner is often mandatory at parting line locations and die block intersections. Other
than this, corners of diecastings should have radii to prevent early die failure, to reduce the
probability of nicking the edge of the diecasting in handling, and to minimise material handling
hazards for personnel.

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