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Valve Body Casting Design

Question asked by Allan Bodaghi on Oct 28, 2018
Latest reply on Oct 29, 2018 by Dave Bear

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I have been trying to design a valve body that is made by casting. I have tried using loft in surfaces and create a internal surface, then thicken the surface to get a solid. but the result are not matching the print. My question how can one design a complex shape like valve body casting using solid works and have control over the filet sizes, etc.? also something else which is important in modeling this design is that the flow cross section should be consistent through the valve. meaning the flow cross section area should be equal to area of a circle with 2" diameter. so when height of cross section is reduced the cross section becomes and eclipse.

Thanks,

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Dave Bear Oct 29, 2018 8:46 AM
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Hi Allan,

Where does this design/drawing come from and were there any others with it?
The reason I ask is although you state that a flow area must be maintained of 2 inches, the aperture in the centre is 2-1/2 inches wide which would make it an ellipse correct? If this is the case surely there would be drawings showing the extent of this ellipse and all ellipses for that matter?
I also note there there is no form or detail of any fittings, threads or even signs of outlets being externally hexagonal.

Dave.
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Shawn Stugard Oct 29, 2018 8:55 AM
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One thing that will help is to keep all your fillets, drafts and chamfers at the end of your feature tree. You'll need to experiment with the order that those features (especially fillets) occur, in order to get the required results.
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- Dave Bear @ Shawn Stugard on Oct 29, 2018 9:05 AM
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  Shawn Stugard wrote:
  
  One thing that will help is to keep all your fillets, drafts and chamfers at the end of your feature tree. You'll need to experiment with the order that those features (especially fillets) occur, in order to get the required results.
  
  Hi Shawn
  Terrific tip indeed but I think he's got wayyyyyy bigger fish to fry before he gets to that point!
  
  Dave.
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  - Shawn Stugard @ Dave Bear on Oct 29, 2018 9:13 AM
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    Hi Dave,
    
    True.... I was replying to his inquiry about controlling fillets and such. But he'll get to that point soon enough, and hopefully save some frustration when he does.
    
    -Shawn
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Allan Bodaghi Oct 29, 2018 9:38 AM
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HI There,
to answer your question this is just a sample drawing i found on the internet and there are no other sections. I was actually looking for samples to see how a complicated casting is depicted in a engineering drawing. and I plan to do a very similar design in the future.
I was able to finish the design by following the actual manufacturing process. so I: made this sketch and used it to make a solid body core by loft and guide curves (which worked out pretty good). then I made the solid outer body and subtract the core from the body.
Now here is the But:
As Shawn Stugard mentioned here, when I am modeling the Solid outer Body and adding the fillets at the end. as you can see in the drawing the fillet of the inlet passage to the 4" Dia. piece is different on the top (5/8") than the bottom(1/4"). but this is circular path so the fillet command will pick up the whole path and therefore the fillet all around will be same Radii.
I will post an image later today so you guys can see what I mean.

Thank for the help.
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Dave Bear Oct 29, 2018 9:46 AM
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Variable fillet?

Dave.
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- Allan Bodaghi @ Dave Bear on Oct 29, 2018 10:56 AM
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  Variable filet did not work, I split the surface and then used the variable filet 5/8" for the top and 1/4" for the bottom but it did not work.
  is it just me or fillets are a pain to work with?
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  - Dave Bear @ Allan Bodaghi on Oct 29, 2018 11:41 PM
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    Allan Bodaghi wrote:
    
    Variable filet did not work, I split the surface and then used the variable filet 5/8" for the top and 1/4" for the bottom but it did not work.
    is it just me or fillets are a pain to work with?
    
    Yep! Fillets can be a PITA.
    And as Shawn Stugard previously mentioned, they can sometimes be an artform in themselves dependent on the way you apply them.
    
    Dave.
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Paul Salvador Oct 29, 2018 9:49 AM
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Hello Allan,.. see if this past thread helps with creating the core...
How to model Control valve (attached image)
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- Allan Bodaghi @ Paul Salvador on Oct 29, 2018 10:56 AM
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  Thank you for sending this but this valve body is much simpler that what i am trying to archive. that valve body can be made with a revolve and a extrude.
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  - Paul Salvador @ Allan Bodaghi on Oct 29, 2018 1:11 PM
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    Allan,... it's for reference.. please look again, the core is made with surfaces,..(correction) "Lofts" and yes, the outside is made with analytical bodies.
    ..that is,.. you can use the cores and thicken..
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Christian Chu Oct 29, 2018 11:04 AM
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Allan,
Can you post your model here. it's hard to say from a cut-section - By the way, is this a sand-casting? if yes, then be careful for complicate surfaces
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Valve Body Casting Design

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