Development of a cost-effective technique for batch production of precision wax patterns using 3D optical inspection and rapid tooling technologies

Kuo, Chil-Chyuan; Tasi, Yun-Ray; Chen, Mingyang; Yan, Zhengyu

doi:10.1007/s00170-021-07763-3

Cited by 5 publications

(2 citation statements)

References 69 publications

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“…This implies that high accuracy and detail are possible to achieve [ 2 ]. In 2021, Chyuan et al [ 3 ] compared the dimensional accuracies of wax patterns manufactured using MJP and FFF-based rapid tooling. They concluded that the direct manufacturing of wax patterns using MJP technology is costly and, therefore, less expensive manufacturing routes can be selected with the help of rapid tooling.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Warpage Phenomenon of Wax Parts Manufactured by Fused Filament Fabrication

Mukhtarkhanov,

Shehab,

Ali

2024

Polymers

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Warpage is one of the prominent issues in Fused Filament Fabrication. The cause of this is the rapid cooling of the polymer during extrusion. The residual thermal stresses accumulated within the print part result in a shape distortion and subsequent detachment of the object from the print bed. In this study, both experimental and numerical approaches were used to identify the stresses due to thermal shrinking that occurs in soft polymers such as wax. A temperature sweep test was performed using a rotational rheometer to measure the magnitude of axial forces that are generated due to the thermal shrinking of a thin layer of 3D printable wax. The thermal stresses responsible for warpage were computed analytically and using the FEA. It was found that due to thermal processes, the stress magnitude can reach a value of 1.17 MPa. This value is enough to cause the plastic deformation in the wax part having a thin elongated shape. In addition, Taguchi’s robust design has identified two major FFF parameters that impact the warpage in amorphous soft polymers. They are the printing speed and the print bed temperature. To achieve a low level of warpage, it is important to make sure that the layer deposition occurs at medium speeds and the print bed temperature is moderately high according to the findings of this study.

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Section: Introductionmentioning

confidence: 99%

Experimental Study on Warpage Phenomenon of Wax Parts Manufactured by Fused Filament Fabrication

Mukhtarkhanov,

Shehab,

Ali

2024

Polymers

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“…AM is a layered manufacturing technique which is an advancement in rapid prototyping (RP) production. It is a non-conventional method of production that eliminates the traditional manufacturing elements such as tools, machining process, jigs, and fixtures [ 1 , 2 ]. AM techniques such as fused deposition modeling (FDM) have their application in our day-to-day life.…”

Section: Introductionmentioning

confidence: 99%

Impact of Process Variables of Acetone Vapor Jet Drilling on Surface Roughness and Circularity of 3D-Printed ABS Parts: Fabrication and Studies on Thermal, Morphological, and Chemical Characterizations

et al. 2022

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Ever since the introduction of 3D printing, industries have seen an exponential growth in production and efficiency. Three-dimensional printing is the process of additive manufacturing (AM) in which the conventional method of material removal is challenged. Layer-on-layer deposition is the basic principle of the AM. Additive manufacturing technologies are used to create 3D-printed objects. An object is built in an additive technique by laying down successive layers of material until the object is complete. Each of these layers can be viewed as a cross-section of the item that has been lightly cut. When compared to traditional production methods, 3D printing allows the creation of complicated shapes with less material. In conventional methods, the materials go through several damages due to the tool–workpiece contact creating friction between them and the dissipated heat that damages the material. Overcoming the conventional method of machining with the help of 3D printing is a new advancement in the industries. The process involves using non-conventional methods for the machining of the parts. This research was oriented towards the chemical vapor jet drilling of the acrylonitrile–butadiene–styrene (ABS) materials. ABS materials are highly machinable and can be recycled for further usage. This paper focused on the usage of acetone as the chemical for drilling. The surface roughness and circularity of the drilled hole was taken into account for this research paper. We set up a manual experiment to run tests and get results. A vapor jet machine was designed with acetone as the core for the vapor. Various analyses were also formulated and conducted during experimentations. Surface roughness analysis provided the insight of roughness after the machining with the help of acetone vapor jet spray. SEM and micro-image parameters were also considered for more clear and advanced reports. In this research paper, DSC and FTIR analysis were performed to understand changes in the internal structure and the material properties of the ABS. Moreover, the research aimed to investigate the effect of various inputs processing parameters such as pressure, flow rate, and stand-off distance on the surface roughness and circularity of ABS workpiece material. The Taguchi L9 orthogonal array design was utilized to conduct tests by chemical vapor jet drilling using acetone and to evaluate the performance of the set-up while reducing the influence of interfering factors in order to provide reliable surface finish and circularity results. The results and conclusion of the research paper aimed to determine the most suitable parameters for the non-conventional acetone vapor jet drilling of the ABS material. The theoretical calculations predicted 1.64432 and 0.3289080 values of surface roughness and circularity, respectively. On the other hand, the experimental values were recorded as 1.598 for surface roughness and 0.322 for circularity. Therefore, a negligible error of 0.046 for surface roughness and 0.0031 for circularity, respectively, was noted which validate the statistical equations and the consistency of the combined vapor jet drilling process.

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An Effective Way of Reducing the Wax Pattern Shrinkage to Improve the Dimensional Accuracy of the Investment Castings

Pattnaik,

Sutar

2023

Springer Proceedings in Materials

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Development of a cost-effective technique for batch production of precision wax patterns using 3D optical inspection and rapid tooling technologies

Cited by 5 publications

References 69 publications

Experimental Study on Warpage Phenomenon of Wax Parts Manufactured by Fused Filament Fabrication

Experimental Study on Warpage Phenomenon of Wax Parts Manufactured by Fused Filament Fabrication

Impact of Process Variables of Acetone Vapor Jet Drilling on Surface Roughness and Circularity of 3D-Printed ABS Parts: Fabrication and Studies on Thermal, Morphological, and Chemical Characterizations

An Effective Way of Reducing the Wax Pattern Shrinkage to Improve the Dimensional Accuracy of the Investment Castings

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