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EN
There are many different casting technologies and their selection depends on the criteria to be met by a cast made. One of the less frequently used precision casting technology is a technology that uses gypsum block forms. From many years are available pre-mixed gypsum for the various alloys, and mold making technology itself can be based on melted wax models or models permanent removed from the mold after hardening the gypsum mix. In case of use permanent models to produce them may be used various types of flexible materials. This solution allows you to make complicated models that can be removed from the mold only by the fact that they are flexible and at the same time capable of large elastic deformations.
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Content available remote Using 3D scanner as a tool for the verification of prototype casting shape
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EN
The aim of the present study is to review information on modern methods of measurement engineering. The article illustrates the three-dimensional scanning of prototype casting and compares the results with a virtual solid model, developed from flat file in a 3D graphic editor. The results of scanning are presented together with specified dimensions and colour map on the model surface. For scanning (digitising), an ATOS III optical scanner, which allows measurement of objects in sizes ranging from a few millimetres to a few dozen meters, was used. This technique can be used in the measurement of both casting and pattern tooling.
PL
W artykule przedstawiono propozycję obniżenia energochłonności wykonania półfabrykatów elementów przekładni planetarnej dzięki zastosowaniu technologii odlewniczej. W pierwszej kolejności dokonano analizy ilości skrawanego materiału dla wytwarzanych elementów w technologii wytaczania z pełnej bryły oraz dla surowych odlewów. Następnie opracowana została technologia odlewania poszczególnych elementów, dla której oprzyrządowanie wykonano przy zastosowaniu metod szybkiego prototypowania. Efektem prowadzonych prac było uzyskanie serii odlewów prototypowych, przeznaczonych do testów eksploatacyjnych oraz uruchomienie produkcji analizowanych podzespołów przekładni planetarnej.
EN
The article presents a proposal for reduced energy consumption level when making semi-finished components of the planetary gear by casting technology. First, an analysis was made of the material volume removed from elements machined by boring from a full block as compared with raw castings. Then the casting technology was developed for different elements, for which tooling was made by the rapid prototyping technique. The result of the work was obtaining a series of prototype castings intended for field testing, and launching the production of the analysed components of the planetary gear.
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EN
The present article describes selected aspects of investment casting technology for manufacturing of open-cell aluminium. The main focus is, among others, on the precursor thickening. Two groups of total 30 samples were produced, basing on open-cell polyurethane foam used as the precursor. Each of the two sample groups was thickened with a different type of suspension consisting of carbonaceous substances and organic binders. The influence of the coating mixture type was compared, leading to conclusions regarding the desired composition and fluidity of the suspensions. Both sample groups of the obtained open-cell aluminium had stochastic cell distributions, the average pore diameter was 5.2 mm and the PPI index was 8. The apparent densities were respectively: 0.485 g/cm3 and 0.312 g/cm3 , which reflected the impact of the precursor coating. Additionally, samples from both groups differed in quality.
PL
W artykule zostały przedstawione techniki powstawania prototypowych odlewów z zastosowaniem połączenia technologii odlewniczych z technikami szybkiego prototypowania. Pokazano kolejne etapy procesów wykonywania odlewów gazo-hamulca, części uchwytu kierownicy, odbojnika pojazdu gąsienicowego, elementu stawu kolanowego.
EN
The techniques of the creation of prototype castings using a combination of casting technologies and rapid prototyping techiques are presented in the paper. The successive stage of he gas-brake part, steering handle, tracked vehicle and knee joint casting process are shown.
EN
The modern designing techniques and development procedures requires the use of advanced integrated methods. That kind of approach requires the involvement of series of steps which leads to the logical work stream known as Integrated Computational Material Engineering. The steps involve the design and evaluation process in the virtual environment of CAD/CAE and simulation software. The use of simulation software allows for online optimization of the shape and properties of designed part. The publication presents a design and manufacturing process of a component of the larger assembly of the chassis of heavy-duty machine. Established methodology includes the analysis of the initial geometry of the part of the heavy vehicle used in difficult wetland environmental conditions.
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EN
In 2014 we finished research works involved in the development of a technology for manufacturing innovative ceramic-carbon foam filters for molten metal alloys filtration, which were financed by the National Centre for Research and Development (NCBiR) from INNOTECH programme resources. A batch of the filters produced in this technology was tested in practice in domestic cast steel and cast iron foundries. The trials were successful and foundries declared their intention to purchase the newly-developed filters for the current production of casts. This provided an incentive for “Ferro-Term” Sp. z o.o. to start design works on the prototype line for a serial production of these filters. At the same time, in co-operation with a scientific consortium, including the co-authors of the technology, i.e. the Institute of Ceramics and Building Materials, Refractory Materials Division in Gliwice, Institute for the Chemical Processing of Coal in Zabrze and Foundry Research Institute in Cracow, the company made a successful attempt to raise some funds for the necessary adaptation of the developed technology from the semi-technical to industrial scale from Intelligent Development Operational Programme. In the article we have presented information on the effects of works performed within the framework of the project entitled “Modernization and adaptation of the existing technological line for purposes related to technology verification and start-up of the production of innovative ceramic-carbon filters for molten metal alloy filtration”.
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