Filling mechanism for prototype parts produced by vacuum differential pressure casting technology

Kuo, Chil-Chyuan; Qiu, Wei-Kai; Liu, Hsueh-An; Chang, Chao-Ming

doi:10.1007/s00170-019-04386-7

Cited by 7 publications

(4 citation statements)

References 43 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Turntables installed in the vacuum chamber allow the filling of multiple molds in one pressure cycle. The cycle time can also be reduced by conventional VDPC systems, as described in Process flow Section [124]. Further measures to automate the process would be conceivable.…”

Section: Decreasing the Cycle Timementioning

confidence: 99%

Industrial‐scale vacuum casting with silicone molds: A review

Wortmann

Frese

2022

Applied Research

View full text Add to dashboard Cite

Vacuum casting (VC) of reactive polymer resins in silicone molds is one of the oldest rapid tooling methods. It is widely used in the industry for prototype and small‐series production of thermoset plastic parts. Despite its widespread use, its scientific exploration is still scarce compared to other prototyping methods, such as three‐dimensional (3D) printing. Compared to conventional 3D printing methods, a wide range of excellent material properties can be achieved, making it well suited for the production of functional prototypes and even final products. The properties of the thermosets are comparable to those of injection molding in terms of viable shapes, mold fidelity, and material properties. However, due to the high cycle time and limited service life of the molds, VC is rarely utilized for mid‐ or large‐series production. Here, we provide a comprehensive overview of the state of the art and recent advances in the field. The review also provides a detailed technical introduction to the mold production, the process flow, and the materials used. A particular focus is on the key challenges facing industrial‐scale VC today—how to reduce cycle time, and how to increase mold service life?

show abstract

Section: Decreasing the Cycle Timementioning

confidence: 99%

Industrial‐scale vacuum casting with silicone molds: A review

Wortmann

Frese

2022

Applied Research

View full text Add to dashboard Cite

show abstract

“…In addition, the hollow cavity in sand mold is not designed close to the desired shape but is designed in an approximate shape for casting. [6][7][8][9][10] After solidification, excess removal of the gating system and risers as post-casting process to cut the casting according to the desired shape are essential processes of sand casting. That means, more materials are wasted than materials desired shape, and the time and cost for the post-casting process are quite large, which is the biggest disadvantage of sand casting.…”

Section: Introductionmentioning

confidence: 99%

“…That means, more materials are wasted than materials desired shape, and the time and cost for the post-casting process are quite large, which is the biggest disadvantage of sand casting. [1][2][3][4][5][6][7][8][9][10][11][12][13] To reduce the amount of wasted material, it is necessary to design a gating system suitable for the desired shape and to verify and supplement the gating system through casting simulation.…”

Section: Introductionmentioning

confidence: 99%

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Jin

2023

Advances in Mechanical Engineering

View full text Add to dashboard Cite

Bottom-up gated filling system was performed to produce worm wheel through a sand casting of zinc alloy. It was a symmetrical design in which two worm wheels were cast at once, the worm wheel was erected in the direction of gravity and had a gating system in which molten zinc alloy were poured from below. The recovery rate of the designed mold cavity was 60%. Casting analysis was performed to check that the worm wheel was sequentially filled without turbulent flow as the molten zinc alloy passed through the gate. Though the speed of the molten zinc alloy initially poured was unstable, it became stabilized while maintaining a constant speed due to the continuous inflow. The results of directional solidification were confirmed. An integrated mold cavity pattern was fabricated by 3D printer, and sand mold were manufactured accordingly. A sound worm wheel without defects could be fabricated through sand casting.

show abstract

“…Zhang et al [ 6 ] optimized the performance of 3D-printed gears using a machine learning process using a genetic algorithm-based artificial neural network multi-parameter regression model; the authors found that the wear performance of 3D-printed gears was increased by three times. Vacuum casting (VC) [ 7 , 8 ] is a promising technique used for the production of functional parts due to its fast production of high-quality prototypes. Oleksy et al [ 9 ] manufactured the gear wheels with epoxy composites using VC technology and found that developed multi-stage homogenized hybrid-filled epoxy resin had a regular layered morphology.…”

Section: Introductionmentioning

confidence: 99%

Characterizations of Polymer Gears Fabricated by Differential Pressure Vacuum Casting and Fused Deposition Modeling

Kuo

Lin

et al. 2021

Polymers

Self Cite

View full text Add to dashboard Cite

In recent years, polymer gears have gradually become more widely employed in medium or heavy-duty conditions based on weight reduction in transmission systems because of low costs and low noise compared to metal gears. In the current industry, proposing a cost-effective approach to the manufacture of polymer gears is an important research issue. This paper investigates the wear performance of polymer gears fabricated with eight different kinds of materials using differential pressure vacuum casting and additive manufacturing techniques. It was found that both additive manufacturing and differential pressure vacuum casting seem to be an effective and cost-effective method for low-volume production of polymer gears for industrial applications. The gate number of one is the optimal design to manufacture a silicone rubber mold for differential pressure vacuum casting since the weld line of the polymer is only one. Polyurethane resin, 10 wt.% glass fiber-reinforced polylatic acid (PLA), or 10 wt.% carbon fiber-reinforced PLA are suggested for manufacturing gears for small quantity demand based on the deformation and abrasion weight percentage under process conditions of 3000 rpm for 120 min; epoxy resin is not suitable for making gears because part of the teeth will be broken during abrasion testing.

show abstract

Filling mechanism for prototype parts produced by vacuum differential pressure casting technology

Cited by 7 publications

References 43 publications

Industrial‐scale vacuum casting with silicone molds: A review

Industrial‐scale vacuum casting with silicone molds: A review

Gating system design and casting simulation application for the grooved worm wheel by using zinc alloy sand casting process

Characterizations of Polymer Gears Fabricated by Differential Pressure Vacuum Casting and Fused Deposition Modeling

Contact Info

Product

Resources

About