Investigations for a statistically controlled rapid casting solution of lead alloys using three-dimensional printing

Singh, Jagdeep; Singh, Rupinder

doi:10.1243/09544062jmes1337

Cited by 46 publications

(36 citation statements)

References 8 publications

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“…In addition, the fundamental tolerance 'i' is not evaluated separately for each nominal size, but for a range of nominal sizes. The fundamental tolerance 'i' and tolerance unit 'n' are calculated by the following equations [27,28]:…”

Section: Calculation Of Tolerance Gradesmentioning

confidence: 99%

Experimental investigations for dimensional accuracy and surface finish of polyurethane prototypes fabricated by indirect rapid tooling: a case study

Singh

Singh²,

Singh³

2017

Prog Addit Manuf

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In this research work, an effort has been made to study the influence of selected input parameters on the dimensional accuracy (linear as well as radial) and surface finish of polyurethane prototypes fabricated by vacuum casting (VC) process as a case study. The master pattern required for making a silicone mould has been fabricated by fused deposition modelling and its surface finish has been enhanced by chemical vapour smoothing process. Maximum shrinkage of 2.29 and 4.77% has been observed in the selected linear and radial dimension, respectively, after the VC process. Optimal parameter settings that were different for both the dimensions as well as surface finish have been obtained using Taguchi's L18 orthogonal array. Finally, parameter setting that simultaneously minimizes the dimensional deviation and surface roughness has been found out using response optimization module of Minitab 17 software and the results obtained have been verified by performing the confirmation experiments. The tolerance grades for the selected dimension of the prototypes were found to be acceptable as per the ISO standard UNI EN 20286-I (1995) and DIN16901 for plastic materials. In addition, the C pk value greater than 1.3 indicated that the proposed process is highly capable. The surface finish and dimensional accuracy of prototypes are at par with the traditional moulding patterns, and hence, they can be used as end-products or plastic-based master patterns for investment casting applications.

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Section: Calculation Of Tolerance Gradesmentioning

confidence: 99%

Experimental investigations for dimensional accuracy and surface finish of polyurethane prototypes fabricated by indirect rapid tooling: a case study

Singh

Singh²,

Singh³

2017

Prog Addit Manuf

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“…RP takes virtual designs (from computer aided design (CAD) or from animation modeling software), transforms them into cross-sections, still virtual, and then creates each cross-section in physical space, one after the next until the model is finished (Singh, 2008b). The various commercially available RP processes can be classified on the basis of the base material used to make the prototype (Stampfl and Liska, 2005).…”

Section: Introductionmentioning

confidence: 99%

“…In particular, additive construction applied to the production of dies and electrodes, directly from digital data, is defined as rapid tooling (RT) (Chua and Ho, 1999a). Patterns, cores and cavities for metal castings can be obtained through rapid casting (RC) techniques (Singh and Singh, 2009b). In both cases, since the tooling phase is highly time-consuming, great competitive advantages can be gained (Lee et al, 2004).…”

Section: Introductionmentioning

confidence: 99%

“…A second solution is 3DP technology with the use of a ceramic material which allows the production of complex cavities and cores, suitable for casting light alloys (Radstok, 1999). 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%

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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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“…AM technique has been proved useful in manufacturing alternative tooling for experimentally determining casting parameters such as shell thickness [24]. AM and 3D scanning techniques have been used in enhanced rapid casting to manufacture custom prostheses [25], or clutch replacement parts [26].…”

mentioning

confidence: 99%

Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study

Vosniakos

Michael

Vasileiou

2017

JMMP

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Abstract:The need to manufacture a copy of a mechanical part typically arises when a single replacement part is necessary and is out of stock or out of production altogether. For parts with intricate details and associated accuracy requirements, investment casting may be preferred to machining, for size and detail reasons, or 3D printing, for material reasons. This work applies the digital manufacturing paradigm to one-off vacuum-aided rapid investment casting focusing on the process chain rather than on engineering issues. 3D laser scanning, digital model construction by surface fitting, casting model making by exploiting additive manufacturing, material investigation using scanning electron microscopy, casting simulation exploring process parameter scenarios, as well as the corresponding implementation on a vacuum casting machine are the pertinent interlinked steps and techniques. The added value of this work is that for each process link the important steps and the potential pitfalls are analyzed in detail using as an example a cylinder liner from a model car engine. Quality of the result was quite acceptable, the main benefit of the streamlined approach being that "right-first-time" parts can be achieved.

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Investigations for a statistically controlled rapid casting solution of lead alloys using three-dimensional printing

Cited by 46 publications

References 8 publications

Experimental investigations for dimensional accuracy and surface finish of polyurethane prototypes fabricated by indirect rapid tooling: a case study

Experimental investigations for dimensional accuracy and surface finish of polyurethane prototypes fabricated by indirect rapid tooling: a case study

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

Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study

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