Stainless Steel Ultrasonic Flow Meter Body
Silica-sol investment casting and machining for a component with complex internal cavities, thin-wall mounting features and threaded connections.
Material
Stainless steel
Application
Flow measurement
Manufacturing
Silica-sol investment casting + machining
Supply scope
Cast body with machined end connections and sensor-port threads
Complex cavities. Finished connections.
YTD designed the ceramic-core tooling, combined multiple cores to form the internal cavities, and refined the thin-wall transitions before completing the specified machining.
Product Views
Click any image to enlarge.
Body Overview
The cast body, two assembly ends and side connection features.
Side Profile
The body profile, sensor ports and mounting structure.
Mounting Structure
Three mounting holes and the thin walls connecting them to the main body.
Threaded End Connection
The internal thread and machined outer surface at one assembly end.
Customer Requirements & Our Solution
Customer requirement
YTD’s approach
Customer requirement
Complex internal cavities
The body required internal cavities whose geometry presented a major challenge for the casting process.
YTD’s approach
Combine multiple ceramic cores.
YTD designed the ceramic-core tooling and assembled multiple cores to form the required internal cavities during casting.
Customer requirement
Strength around the mounting structure
The thin walls supporting three mounting holes needed to connect to the main body while preserving the component’s function.
YTD’s approach
Refine the transition geometry.
YTD used the customer’s drawing as the basis for refining the transitions, with attention to structural strength and functional requirements.
Customer requirement
Finished assembly and sensor connections
Both assembly ends and the sensor mounting ports required machined connection features.
YTD’s approach
Complete the specified machining.
YTD machined the outer surfaces and internal threads at both ends, together with the threads in the sensor mounting ports.
Multiple Ceramic Cores for the Internal Cavities
The internal cavities were one of the most demanding features of this project. The casting method needed to account for the geometry inside the part as well as its external shape.
YTD designed the tooling used to make the ceramic cores and combined multiple cores for the casting process. Together, these cores formed the internal cavities during silica-sol investment casting.
Refining the Thin-Wall Connections
The structure supporting three mounting holes connects to the main body through relatively thin walls. These junctions required particular attention during the manufacturing review.
Working from the customer’s drawing, YTD adjusted the transition geometry with the aim of maintaining structural strength while preserving the product’s intended function.
Casting & Machining Scope
Work Completed by YTD
| Feature | Process | Work completed |
|---|---|---|
| Internal cavities | Core tooling and casting | Ceramic-core tooling designed by YTD; multiple cores assembled for casting |
| Mounting structure | Geometry refinement | Adjustments to the thin-wall transitions based on the customer’s drawing |
| Assembly ends | Machining | Outer surfaces and internal threads at both ends |
| Sensor mounting ports | Machining | Threads in the sensor mounting ports |
The Completed Component
- Stainless steel body produced by silica-sol investment casting.
- Internal cavities formed using multiple assembled ceramic cores.
- Refined transitions around the three-hole mounting structure.
- Machined assembly-end surfaces, internal end threads and sensor-port threads.
Inside Our Factory
Explore the tooling, casting, machining and inspection facilities behind YTD’s casting services.
Integrated Production Facility
CNC Machining Center
Slurry Coating
Casting Workshop
Mold Machining
Casted Mold
Steel Mold
Aluminum Mold
CNC Machined Mold
Wax Injection
Slurry Coating
Shell Drying
Dewaxing
Melting & Pouring
Triming
Post Processing
CMM/Hardness/Spectrometer Test
Wax Pattern Check
Wax Pattern Trimming
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Have a Casting with Complex Internal Features?
Share your drawing or 3D model, material specification, quantity and key assembly requirements. YTD can review the internal cavities, thin-wall transitions and machining scope for your project.