cost designs in ductile iron designs in ductile iron … the johnson corp. three rivers, mi foundry...
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CostSavingDesignIdeas
CostSavingDesignIdeas
Designs in Ductile Iron Designs in Ductile Iron
CASTING Hydraulic Motor RearHousing
APPLICATION Allows Changing ofHydraulic MotorDisplacement
SPECIFICATION ASTM A-536 (80-55-06)
REDESIGN Was a Three PieceAssembly of SteelPlate That Required aConsiderable Amount ofMachining
COST SAVINGS Component CostReduced 44%
DESIGN Improved Wear andADVANTAGES Machining Characteristics;
Cost Savings ProvidedCost Competitiveness
SIZE & WEIGHT Approx. 100 lb. Casting
COMPANY Rineer HydraulicsSan Antonio, TX
FOUNDRY Alamo Iron WorksSan Antonio, TX
CASTING Lift Arm
APPLICATION Raise & Lower MotorGrader Blade
SPECIFICATION ASTM A-536 (65-45-12)
REDESIGN From Steel Casting
COST SAVINGS Part Cost Reduced 47%
DESIGN Lower ManufacturingADVANTAGES Costs
SIZE & WEIGHT Unknown
COMPANY Caterpillar Inc.Decatur, IL
FOUNDRY Unknown
CASTING Forward-Reverse Gear
APPLICATION Power TransmissionPart
SPECIFICATION ASTM A-536 (100-70-03)
REDESIGN From Steel Forging,Steel Stamping, andShaft
COST SAVINGS $402,000 AnnualSavings
DESIGN High Fatigue Strength;ADVANTAGES Good Response to Heat
Treatment; ReducedNumber of Parts;Reduced Operationsfrom 18 to 9
SIZE & WEIGHT 6" Diameter Gear
COMPANY Unknown
FOUNDRY Dotson CompanyMankato, MN
CASTING Syphon Elbow
APPLICATION Condensate RemovalFrom Paper Dryer
SPECIFICATION ASTM A-536 (60-40-18)Investment Cast
REDESIGN From Bronze
COST SAVINGS Cost Reduced 10% PerPart
DESIGN Increased Strength;ADVANTAGES Reduced Machining Time
SIZE & WEIGHT 5 oz. to 2 lbs. 11 oz.
COMPANY The Johnson Corp.Three Rivers, MI
FOUNDRY Unknown
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP20 21
CostSavingDesignIdeas
CostSavingDesignIdeas
Designs in Ductile Iron Designs in Ductile Iron
CASTING Gland
APPLICATION Hydraulic Cylinder
SPECIFICATION ASTM A-536 (65-45-12)
REDESIGN From Gray Iron Casting
COST SAVINGS Part Cost Reduced66%; ReducedOperations from 10 to 3
DESIGN Stronger; Quality isADVANTAGES Improved; Better
Machinability; MoreEconomical
SIZE & WEIGHT Variable
COMPANY Seitz Mfg. Co. Inc.Milwaukee, WI
FOUNDRY Unknown
CASTING Steering Column Support
APPLICATION Support Steering Column;Absorb Air Bag and CrashLoads
SPECIFICATION SAE J-434C (D4512)
REDESIGN From Steel Weldments andMultiple Stampings
COST SAVINGS Unknown
DESIGN Stronger; ImprovedADVANTAGES Performance Safety
Related Part
SIZE & WEIGHT 15" x 4"
COMPANY Wagner CastingDecatur, IL
FOUNDRY Same as Above
CASTING Clutch Cup
APPLICATION Farm Tractor PowerTake-Off
SPECIFICATION ASTM A-536(100-70-03)
REDESIGN From Steel Forging
COST SAVINGS Part Cost Reduced 32%;$112,000 Annual Savings
DESIGN Substantial Cost SavingsADVANTAGES While Still Retaining
Tensile and YieldStrengths
SIZE & WEIGHT 6" x 5"
COMPANY International HarvesterRock Island, IL
FOUNDRY International HarvesterMemphis, TN
CASTING Air Suspension Hanger
APPLICATION Converter Dolly
SPECIFICATION ASTM A-536 (80-55-06)
REDESIGN From Steel Weldment
COST SAVINGS Part Cost Reduced 53%;$58,000 Annual Savings
DESIGN Increased Service LifeADVANTAGES 10-15 Times; Decreased
Assembly Time 83%;Eliminated Welding
SIZE & WEIGHT Approx. 12"
COMPANY Todco Div. Overhead DoorHaywood, CA
FOUNDRY Atlas Foundry & Mfg.Richmond, CA
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP22 23
CostSavingDesignIdeas
CostSavingDesignIdeas
Designs in Ductile Iron Designs in Ductile Iron
CASTING Plug Valves
APPLICATION Fluid Handling
SPECIFICATION ASTM A-536 (60-40-18)
REDESIGN From Stainless Steel,Titanium, Monel
COST SAVINGS Part Cost Reduced66%; $3,000,000 Annual Savings
DESIGN Provided CloseADVANTAGES Dimensional Tolerances;
Facilitated Installation ofPlastic Liner
SIZE & WEIGHT Various
COMPANY Continental Mfg.Cincinnati, OH
FOUNDRY Lynchburg FoundryLynchburg, VA
CASTING Tool Storage Index
APPLICATION N/C Machining Center
SPECIFICATION ASTM A-536 (80-55-06)
REDESIGN From Steel Weldment
COST SAVINGS Part Cost Reduced 80%
DESIGN Reduced ProductionADVANTAGES Operations from 2,115
to 24; Improved Appearance
SIZE & WEIGHT Unknown
COMPANY National Automatic ToolRichmond, IN
FOUNDRY Unknown
CASTING Rear Engine Mount
APPLICATION Engine Support andTorque ReactionMember
SPECIFICATION SAE J-434C (D4512)
REDESIGN From Steel Stamping
COST SAVINGS Lowered Tooling & PerPiece Costs
DESIGN Stiffer Design; 38%ADVANTAGES Weight Reduction; More
Compact Product GivesLess PackagingInterference Problems
SIZE & WEIGHT 5" x 4"
COMPANY Ford Motor Co.
FOUNDRY Wagner CastingDecatur, IL
CASTING Crankcase
APPLICATION Air Compressor
SPECIFICATION ASTM A-536 (60-40-18)
REDESIGN From Steel Weldment
COST SAVINGS Part Cost Reduced82%; $100,000 AnnualSavings
DESIGN Better Resistance toADVANTAGES Shock Damage;
Improved SoundDampening
SIZE & WEIGHT 48" x 36" x 72"
COMPANY Worthington Corp.Harrison, NJ
FOUNDRY Unknown
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP24 25
DUCTILE IRON SOCIETYFOUNDRY MEMBERS
Aimco Foundry Corporation3300 N. SylvaniaFt. Worth, TX 76111817-838-2301 • Fax 817-831-3609
Alabama Ductile Casting Company123 St. Joseph StreetBrewton, AL 36426205-867-5481 • Fax 205-867-8638
American Cast Iron Pipe Company1501 31st Avenue NorthBirmingham, AL 35202-2727205-325-7954 • Fax 205-325-8921
Baker Manufacturing Company133 Enterprise StreetEvansville, Wi 53536608-882-5100 • Fax 608-882-6776
Bay Engineered Casting Company1900 Enterprise DriveDePere, WI 54115414-336-5781 • Fax 414-336-3567
Berlin Foundry Corporation242 South Pearl StreetBerlin, WI 54923414-361-2220 • Fax 414-361-4017
Briggs & Stratton CorporationCastings Division1706 S. 68th StreetWest Allis, WI 53214414-259-5333 • Fax 414-259-5959
Buck Company, Inc.897 Lancaster PikeQuarryville, PA 17566717-284-4114 • Fax 717-284-3737
CifnusaBlvd. Isidro Lopez 1255Saltillo, Coahuila 25000Mexico52-84-158316Fax 52-84-158496
CMI International, Inc.30333 Southfield Rd.Southfield, MI 48076313-642-9450 • Fax 313-642-4955
CMI Tech Center, Inc.1600 West Eight Mile RoadFerndale, MI 48220313-399-9600 • Fax 313-399-3512
CMI-Cast Parts, Inc.A CMI International Co.1500 Fourth AvenueCadillac, MI 49601616-779-9600 • Fax 616-779-9640
CT-South, Inc.Route 45 SouthMarion, AL 36756205-683-6101 • Fax 205-683-8365
CWC CastingsA Divison of Textron, Inc.1085 W. Sherman Blvd.Muskegon, MI 49441-3588616-733-1331 • Fax 616-739-2649
Cast-Fab Technologies, Inc.3040 Forrer StreetCincinnati, OH 45209513-758-1000 • Fax 513-758-1002
Chrysler Corporation12800 Oakland AvenueHighland Park, MI 48288-1118313-956-3750 • Fax 313-252-6310
Citation Corporation2 Office Park CircleBirmingham, AL 35243205-871-5731
Columbus Foundries, Inc.An Intermet Corporation Co.1600 Northside Ind. Blvd.Columbus, GA 31995404-323-5221 • Fax 404-324-1138
Cooper IndustriesIndustrial Machinery Division700 MainLa Grange, MO 63448314-655-2291 • Fax 314-655-4361
Donsco, Inc.North Front StreetWrightsville, PA 17368717-252-1561 • Fax 717-252-4530
Dotson Company, Inc.200 W. Rock St.Mankato, MN 56001507-345-5018 • Fax 507-345-1270
Ellwood Engineered Castings7158 Masury Rd., S.E.Hubbard, OH 44425216-534-8668 • Fax 216-534-0069
Enterprise Foundry, Inc.South AvenueLewiston, ME 04241-1564207-782-5511 • Fax 207-783-0897
Ford Motor CompanyBrook Park5600 Henry Ford Blvd.Brook Park, OH 44142216-676-7113
Ford Motor CompanyCanadaWindsor, Ontario N9A 2S5Canada519-257-4502
Ford Motor CompanyDearborn3001 Miller RoadDearborn, MI 48120313-322-4943 • Fax 313-845-1716
Foundry Service Company530 E. Main StreetBiscoe, NC 27209919-428-2111 • Fax 919-428-4986
Francis & Nygren Foundry Company6911 W. 59th StreetChicago, IL 60638773-586-7100 • Fax 773-586-7117
Frazier & Frazier IndustriesSouth 1st StreetCoolidge, TX 76635817-786-2293 • Fax 817-786-2284
G.M. Powertrain DivisionMassena, NY315-764-2321
G.M. of Canada Foundry570 Glendale AvenueSt. Catharines, Ontario L2R 7B3Canada416-641-6550 • Fax 416-641-6361
General Casting CompanyCincinnati Division1740 Powers StreetCincinnati, OH 45223513-541-6121 • Fax 513-541-0628
General Casting CompanyDelaware Division550 S. Liberty RoadDelaware, OH 43015614-363-1941 • Fax 614-363-0103
General Casting CompanyDomestic DivisonN. Queen StreetShippensburg, PA 17257717-532-6615 • Fax 717-532-3743
General Casting CompanyEdwin Poulton Foundry1071 Goodale Blvd.Columbus, OH 43212614-224-3750 • Fax 614-224-5863
General Casting CompanyToledo Street Division148 Toledo StreetDelaware, OH 43015614-363-1941 • Fax 614-363-0103
Glidewell SpecialtiesFoundry Co.600 Foundry RoadCalera, AL 35040205-668-1881 • Fax 205-668-1972
Globe Iron Foundry, Inc.5649 E. Randolph StreetLos Angeles, CA 90040213-723-8983 • Fax 213-888-9664
Grede Foundries, Inc.9898 W. Bluemound RoadMilwaukee, WI 53226414-257-3600 • Fax 414-257-4102
Grede Foundries, Inc.Liberty Foundry6432 W. State StreetWauwatosa, WI 53213414-771-6700 • Fax 414-771-1247
Grede Foundries, Inc.New Castle Foundry2700 E. Plum StreetNew Castle, IN 47362317-521-8000 Fax 317-521-8000 ext. 224
Grede Foundries, Inc.Reedsburg Foundry700 Ash StreetReedsburg, WI 53959608-524-6424 • Fax 608-524-9501
Grede Foundries, Inc.Wichita Foundry805 E. BostonWichita, KS 67211316-262-7204Fax 316-262-7204 ext. 346
Gregg Industries, Inc.10460 HicksonEl Monte, CA 91734818-575-7664 • Fax 818-401-0971
Grinnell Corporation1411 Lancaster AvenueColumbia, PA 17512717-684-4400 • Fax 717-684-2131
Harrison Steel Castings Company900 Mound StreetAttica, IN 47918317-762-2481 • Fax 317-762-2487
Harvard Industries, Inc.Albion Plant601 North Albion StreetAlbion, MI 49224517-629-2141 • Fax ext. 212
Harvard Industries, Inc.Jackson Operation1999 Wildwood AvenueJackson, MI 49202517-782-9421 • Fax 517-782-4478
Harvard Industries, Inc.Tiffin Division745 S. Seneca County Road 13Tiffin, OH 44883419-448-9310 • Fax 419-447-3357
Hodge Foundry, Inc.42 Leech RoadGreenville, PA 16125412-588-4100 • Fax 412-588-0152
Intermet Corporation 2859 Paces Ferry RoadSuite 1600Atlanta, GA 30339404-431-6000
John Deere Foundry Waterloo2000 Westfield AvenueWaterloo, IA 50704-2000319-292-5600 • Fax 319-292-5027
John Deere Technical Center3300 River DriveMoline, IL 61265309-765-3854
Kingsport Foundry & Mfg. Corp.145 Unicoi StreetKingsport, TN 37662615-246-8150 • Fax 615-246-2077
Lufkin Industries601 South RaguetLufkin, TX 75902-0849409-637-5311 • Fax 409-637-5429
Lynchburg Foundry Co.Archer Creek PlantLynchburg, VA 24505804-528-8200
Lynchburg Foundry CompanyAn Intermet Corporation Co.620 Court StreetLynchburg, VA 24505804-528-8200 • Fax 804-528-8301
Lynchburg Foundry CompanyLower Basin PlantLynchburg, VA 24505804-528-8200
Lynchburg Foundry CompanyRadford PlantRadford, VA 24141703-731-0400
Neenah Foundry Company2121 Brooks AvenueNeenah, WI 54957414-725-7000 • Fax 414-729-3652
Noblesville Casting, Inc.1600 South 8th StreetNoblesville, IN 46060317-773-3313 • Fax 317-776-0787
Northern Castings CoporationAn Intermet Corporation Co.555 West 25th StreetHibbing, MN 55746218-263-8871 • Fax 218-263-5039
Ohio Cast Products, Inc.2408 13th Street N.E.Canton, OH 44705216-456-4784 • Fax 216-456-2247
Pier Foundry and Pattern Shop, Inc.51 State StreetSt. Paul, MN 55107612-222-4461 • Fax 612-222-4185
Precision Metalsmiths, Inc.1081 E. 200th StreetCleveland, OH 44117216-481-8900 • Fax 216-481-8903
Precision Metalsmiths, Inc.Midwest Division1149 N. Margaret StreetMarkesan, WI 53946414-398-2361 • Fax 414-398-3644
Quality Castings Company1200 N. Main StreetOrrville, OH 44667216-682-6010 • Fax 216-683-3153
Richmond Casting Company, Inc.1775 Rich RoadRichmond, IN 47374317-935-4090 • Fax 317-935-2168
St. Marys Foundry, Inc.405-409 E. South StreetSt. Marys, OH 45885419-394-3346 • Fax 419-394-8269
Standard Automotive Parts660-666 Nims St.Muskegon, MI 49442616-722-6646 • Fax 616-726-5100
Technocast, Inc.1100 N. Main StreetOrrville, OH 44667216-684-2010 • Fax 216-683-0321
Teledyne Casting Service300 Philadelphia StreetLaPorte, IN 46350219-362-1000 • Fax 219-324-5414
Texas Foundries, Inc.1611 North Raguet (75901)Lufkin, TX 75903-3718409-632-4451 • Fax 409-639-6126
Tyler Pipe IndustriesTyler, TX 75710903-882-5511Fax 1-800-24-TYLER
Valmet Sandy Hill, Inc.27 Allen StreetHudson Falls, NY 12839-0803518-747-3381 • Fax 518-747-1541
Victaulic Company of America4901 Kesslersville RoadEaston, PA 18042215-559-3300 • Fax 215-250-8817
Wagner Castings CompanyDecatur Division825 North LowberDecatur, IL 62525217-428-7791 • Fax 217-425-6662
Ward Manufacturing, Inc.115 Gulick StreetBlossburg, PA 16912-0009717-638-2131 • Fax 717-638-3410
Waupaca Foundry, Inc.311 Tower RoadWaupaca, WI 54981715-258-6611 • Fax 715-258-9268
Wells Manufacturing CompanyCastwell Division7800 North Austin AvenueSkokie, IL 60077-4342847-966-5050 • Fax 847-966-8876
Wells Manufacturing CompanyDura-Bar Division1800 West Lake Shore Dr.Woodstock, IL 60098-7426815-338-7800 • Fax 815-338-8845
Western Foundry Company Limited454 Industrial RoadWingham, Ontario N0G 2W0Canada519-357-3450 • Fax 519-357-2486
Western Foundry Company LimitedBrantford DivisionPowerline Road WestBrantford, Ontario N3T 5W5Canada519-759-0452 • Fax 519-759-8535
Wheland Foundry–Division of NorthAmerican Royalties, Inc.2800 S. Broad StreetChattanooga, TN 37402615-265-3181 • Fax 615-756-3179
DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP26 27