The structure and technical requirements of a monolithic differential housing were introduced,the casting method development process of differential housing produced on DISA molding line was described in details.In the early stage of development using MAGMA numeral simulation software simulated the designed casting method,investigated 3 riser method schemes,then selected the scheme with the best simulation results and the highest process production rate for the actual production and trial production.Trial-production results showed that:the internal defect reached the target of D3/1,the casting appearance defect was 4.8％,and the appearance defect rate after machining was 0.Finally it was pointed out:(1)By using two steps of runners,outer surface sand inclusion eliminating effect was very obvious.(2)By proper riser design,the long axis end hole was not cast out,adopting long axis end being filled,then the shrinkage and filled end could be eliminated by machining and thereby realized the target that the inner defect of differential housing reaching D3/1.
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