Development, evaluation, and selection of rapid tooling process chains for sand casting of functional prototypes

Dimitrov, Dimiter M.; Wijck, W. Van; Beer, N. de; Dietrich, Jochen

doi:10.1243/09544054jem728

Cited by 28 publications

(19 citation statements)

References 6 publications

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“…Other applications include injection mould trials using the EOS Alumide material (de Beer et al, 2005a), and the development of novel RT process chains for large sand casting components (Dimitrov et al, 2007a(Dimitrov et al, , 2007b. The use of RP technologies have increased the fidelity of physical models in terms of aesthetics, ergonomics and functionality.…”

Section: Rp Research and Applicationsmentioning

confidence: 99%

Additive manufacturing in South Africa: building on the foundations

Campbell

Beer²,

Pei³

2011

Rapid Prototyping Journal

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Type of Paper General Review PurposeIn a previous Rapid Prototyping Journal paper, the authors reviewed the first decade of Rapid Prototyping (RP) use within the Republic of South Africa (RSA). The paper analysed its strengths, weaknesses, opportunities and threats, and proposed a "road-map" for future development. Much has happened in the intervening years since that article was published and this paper seeks to update readers on the current situation in RSA. In particular, it reports the extensive development of research in the field of RP and Additive Manufacturing (AM). MethodologyThe paper uses a literature review approach combined with reflective analysis to distill the most important developments within the RP community in RSA since 2004. These are compared to the previous road-map to ascertain if there are any required actions that have been overlooked or any additional lessons that have been learnt. FindingsThe paper shows that there has been good progress against the previous road-map and that current plans should remain in place with the addition of a greater educational dimension. Practical ImplicationsThis paper provides readers with an overview of important RP/AM developments in the RSA.The analysis from this the paper will aid RSA academics, industrialists and government agencies to assess their performance and to plan for their future roles within the RP community. ValueAs with the previous paper, this article provides a useful model for other countries to follow since it demonstrates both good practice but also the need to learn from past experience.

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Section: Rp Research and Applicationsmentioning

confidence: 99%

Additive manufacturing in South Africa: building on the foundations

Campbell

Beer²,

Pei³

2011

Rapid Prototyping Journal

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“…Tomita and Fukuda [54] used 65% artificial sand and 35% natural silica sand to print the sand mould and avoided the veining defect. One big problem for the 3DP method is the clogging of the nozzles of 3DP machines by viscous binder [55] . To guarantee the operation of printers and the mechanical and performance properties during casting process of sand core or mould, some 3D printer companies provide their own specific binders and sands for 3D printing.…”

Section: D Printing Of Sand Core Mould and Shellmentioning

confidence: 99%

The role and impact of 3D printing technologies in casting

Kang¹,

Ma²

2017

China Foundry

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“…A key issue regarding the shell casting process is the production of the pattern in the case of prototype casting, for which traditional die casting is uneconomical (Cheah et al, 2005;Singh, 2008b). RP techniques can meet this requirement, producing single/few parts in a short time and without tooling costs (Dimitrov et al, 2007).…”

Section: Introductionmentioning

confidence: 99%

Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminium using Three Dimensional Printing

Singh¹,

Singh²

2012

Int J Automot Mech Eng

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The purpose of the present work is to study the effect of workpiece volume on reducing the shell wall thickness in rapid shell casting based upon three-dimensional printing (3DP) technology, and to evaluate the dimensional accuracy and mechanical properties of aluminum (Al) castings obtained as per the ISO standard UNIEN 20286-I (1995). Starting from the identification of component/benchmark, castings of different volumes (corresponding to workpieces of Φ60 mm, Φ50 mm and Φ40 mm) were produced with different shell wall thicknesses. Measurements on a coordinate measuring machine (CMM) allowed the calculation of the dimensional tolerances of the castings produced. Some important mechanical properties were also compared to verify the suitability of the castings. The research proved that having a shell wall thickness with a value less than that recommended (12 mm) is more suitable from a dimensional accuracy and economic point of view (irrespective of the workpiece volume within the given selected range). All the castings produced with different shell thicknesses are acceptable as per the ISO standard. The results of the study suggest that workpiece volume has an unnoticeable effect on reducing the shell wall thickness for the selected range of volumes of casting. Furthermore, the hardness of castings produced is almost same for all shell wall thicknesses, from 12 mm to 1 mm. The results are supported by cooling (time-temperature) curves, which show unnoticeable changes in the rate of heat transfer at different shell wall thicknesses. Keeping in mind the cost effectiveness of the process, one (1) mm shell wall thickness has been recommended for the production of castings. For a 1 mm shell wall thickness, the production cost and time are reduced by 67.38% and 44.87% (for Φ60 mm workpieces), 64.51% and 44.62% (for Φ50 mm workpieces), and 69.50% and 59.64% (for Φ40 mm workpieces), respectively.

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Development, evaluation, and selection of rapid tooling process chains for sand casting of functional prototypes

Cited by 28 publications

References 6 publications

Additive manufacturing in South Africa: building on the foundations

Additive manufacturing in South Africa: building on the foundations

The role and impact of 3D printing technologies in casting

Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminium using Three Dimensional Printing

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