Investigations for deducing wall thickness of aluminium shell casting using three dimensional printing

• Autorzy: Singh R. , Verma M.
• Języki publikacji: EN

Abstrakty

EN

Purpose: of the present study is to verify the feasibility of decreasing the shell thickness in rapid shell casting based upon three dimensional printing technology in order to evaluate the dimensional accuracy for aluminum castings. Rapid prototyping has been in evidence for the past twenty years and is being widely used in diverse areas, from the building of aesthetic and functional prototypes to the production of tools and moulds for technological prototypes. Design/methodology/approach: Further consistency with the tolerance grades of the castings has been checked as per IT grades along with mechanical properties of the aluminium castings. Starting from the identification of component/87benchmark, technological prototypes are produced with different shell thicknesses. Measurements on a coordinate measuring machine allowed calculating the dimensional tolerances of the castings produced. Findings: The research proved that the shell thickness having value less than the recommended one is more suitable from dimensional accuracy and economic point of view. The result indicates that at 5 mm shell thickness, hardness of the casting is improved by 3.79%. Further production cost and production time has been reduced by 54.6% and 55.4% respectively in comparison to 12 mm recommended shell thickness. Practical implications: The analysis procedure is better for proof of concept and for the new product, for which the cost of production for dies and other tooling is more. Originality/value: The 3DP technique at different shell thicknesses (12 mm to 2 mm) provided satisfactory results, limited at present to the field of light alloys. This process ensures rapid production of pre-series technological prototypes and proof of concept at less production cost and time.

Słowa kluczowe

EN

rapid prototyping; 3D printing; commercial aluminium alloy; CMM; dimensional tolerance

PL

szybkie prototypowanie; tolerancja wymiarowa

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2008
• Tom: Vol. 31, nr 2
• Strony: 585--589
• Opis fizyczny: Bibliogr. 17 poz., wykr., tab., il.

Twórcy

autor

Singh R.

autor

Verma M.

• Mechanical & Production Engineering Department, Guru Nanak Dev Engineering College, Ludhiana, Punjab, India,

Bibliografia

• [1] I. Ainsworth, M. Ristic, D. Brujic, CAD-based measurement path planning for free form shapes using contact probes, International Journal of Advanced Manufacturing Technology 16/1 (2000) 23-31.
• [2] D. Bak, Rapid prototyping or rapid production? 3D printing processes move industry towards the latter, Rapid Prototyping Journal 23/4 (2003) 340-345.
• [3] E. Bassoli, A. Gatto, L. Luliano, M. G. Violentte, 3D printing technique applied to rapid casting, Rapid Prototyping Journal 13/3 (2007) 148-155.
• [4] A. Bernard, J. C. Delplace, N. Perry, S. Gabriel, Integration of CAD and rapid manufacturing for sand casting optimisation, Rapid Prototyping Journal 9/5 (2003) 327-333.
• [5] E. Chirone, S. Tornincasa, Disegno Tecnico Industriale 2, Il Capitello, Torino, 2004 (in Italian).
• [6] C. K. Chua, K. F. Leong, Rapid Prototyping: principles and applications in manufacturing, John Wiley & Sons Ltd. (2000).
• [7] A. Gatto, L. Luliano, Effect of the post curing process parameters choice on part produced by direct croning process, Proceedings of the 1st International Seminar on „Progress in Innovative Manufacturing Engineering” PRIME'2001, Sestri Levante (Geneva), 2001.
• [8] R. W. Lewis, M. T. Manzari, D. T. Gethin, Thermal optimisation in the sand casting process, Engineering Computations 3/4 (2001) 392-416.
• [9] A. M. Ramos, C. Relvas, J. A. Simoes, Vacuum casting with room temperature vulcanising rubber and aluminium moulds for rapid manufacturing of quality parts: a comparative study, Rapid Prototyping Journal 9/2 (2003) 111-115.
• [10] B. Rooks, Rapid tooling for casting prototypes, Rapid Prototyping Journal 22/1 (2002) 40-45.
• [11] E. M. Sachs, J. S. Haggerty, M. J. Cima, A. P. Wiliams, Three dimensional printing techniques, United States Patent No. US 005340656 (1994).
• [12] S. Ashley, From CAD art to rapid metal tools, Mechanical Engineering 3 (1997) 82-87.
• [13] Y. Song, Y. Yan, R. Zhang, Q. Lu, D. Xu, Three dimensional non-linear coupled thermo-mechanical FEM analysis of the dimensional accuracy for casting dies in rapid tooling, Finite Elements in Analysis and Design 38 (2001) 79-91.
• [14] ISO system of limits and fits: Bases of tolerances, deviations and fits, UNI EN 20286-I (1995).
• [15] W. Wang, J. G. Conley, H. W. Stoll, Rapid tooling for sand casting using laminated object manufacturing process, Rapid Prototyping Journal 5/3 (1999) 134-140.
• [16] T. Wohlers, Future potential of rapid prototyping and manufacturing around the world, Rapid Prototyping Journal 1/1 (1995) 4-10.
• [17] W. Wolovich, H. Albakri, H. Yalcin, The precise measurement of free-form surfaces, Journal of Manufacturing Science and Engineering 124/2 (2002) 326-32.