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Avoid Abrupt Section Changes

The difference in relative thickness of adjoining sections should not exceed a ratio of 2:1. If a greater difference is unavoidable, consider a design with detachable parts, like machine tool beds that can be bolted.

When a change in thickness is less than 2:1, it may take the form of a fillet. When the difference is greater, the recommended shift is in the form of a wedge. However, wedgeshaped changes in wall thickness should not taper more than 1 in 4. Where a combination of light and heavy sections is unavoidable, use fillets and tapered sections to temper the shifts.

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This article was adopted from a section of Casting World Magazine. Reprinted with permission.