Process capability study of three dimensional printing as casting solution for non ferrous alloys

2016 ◽  
Vol 22 (3) ◽  
pp. 474-486 ◽  
Author(s):  
Rajesh Kumar ◽  
Rupinder Singh ◽  
IPS Ahuja
Keyword(s):  
Research Work ◽  
Three Dimensional ◽  
Process Capability ◽  
Dimensional Accuracy ◽  
Ferrous Alloy ◽  
Content Type ◽  
Three Dimensional Printing ◽  
Casting Solution ◽  
Measuring Machine ◽  
Dimensional Printing

Purpose The purpose of this paper is to investigate the process capability of three-dimensional printing (3DP)-based casting solutions for non-ferrous alloy (NFA) components. Design/methodology/approach After selection and design of benchmark, prototypes for six different NFA materials were prepared by using 3DP (ZCast process)-based shell moulds. Coordinate measuring machine has been used for calculating the dimensional tolerances of the NFA components. Consistency with the tolerance grades of the castings has been checked as per IT grades. Findings The results of process capability investigation highlight that the 3DP process as a casting solution for NFA component lies in ±5sigma (s) limit, as regards to dimensional accuracy is concerned. Further, this process ensures rapid production of pre-series industrial prototypes for NFA. Final components prepared are also acceptable as per ISO standard UNI EN 20,286-I (1995). Originality/value This research work presents capability of the 3DP process supported with experimental data on basis of various process parameters for the tolerance grade of NFA castings. These statistics can help to enhance the application of 3DP-based NFA casting process in commercial foundry industry.

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

2009 ◽  
Vol 223 (9) ◽  
pp. 2125-2134 ◽  
Author(s):  
J P Singh ◽  
R Singh
Keyword(s):  
Shell Thickness ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Production Costs ◽  
Economic Point ◽  
Three Dimensional Printing ◽  
Rapid Casting ◽  
Casting Solution ◽  
Measuring Machine ◽  
Dimensional Printing

The purpose of the present investigation is to study the feasibility of decreasing the shell thickness for a statistically controlled rapid casting solution of lead alloy using three-dimensional printing technology. Starting from the identification of a component/benchmark, technological prototypes were produced with different shell thickness. Measurements on a coordinate measuring machine helped in calculating the dimensional tolerances of the castings produced. Some important mechanical properties were also compared to verify the suitability of the castings and further results are supported by microstructure analysis. The study suggested that the shell thickness having a value less than the recommended one is more suitable from a dimensional accuracy and an economic point of view. The provided data from the experimentation are extremely useful for the industrial application of the considered technology. The result indicates that at 1 mm shell thickness, the hardness of the casting improves from the recommended 12 mm. Further, production costs and production time have been reduced by 45.75 and 43 per cent, respectively, in comparison with the 12 mm recommended shell thickness.

Experimental investigations for reducing wall thickness in zinc shell casting using three-dimensional printing

2008 ◽  
Vol 222 (12) ◽  
pp. 2427-2431 ◽  
Author(s):  
M Kaplas ◽  
R Singh
Keyword(s):  
Mechanical Properties ◽  
Shell Thickness ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Zinc Alloy ◽  
Experimental Investigations ◽  
Economic Point ◽  
Three Dimensional Printing ◽  
Measuring Machine ◽  
Dimensional Printing

The purpose of this study is to verify the feasibility of decreasing the shell thickness in rapid casting (RC) process based on three-dimensional printing technology and to evaluate the dimensional accuracy, mechanical properties of RC solutions for the production of zinc-alloy casting. Starting from the identification of component/benchmark, technological prototypes were produced with different shell thickness. Measurements on a coordinate-measuring machine helped in calculating the dimensional tolerances of the castings produced. Some important mechanical properties were also compared to verify the suitability of the castings, and further results are supported by the radiography analysis. The study suggested that the shell thickness having value less than the recommended one is more suitable from dimensional accuracy and economic point of view. The provided data from the experimentation are extremely useful for the industrial application of the considered technology. The result indicates that at 7 mm shell thickness, hardness of the casting improved from the recommended 12 mm. Further, production cost and production time have been reduced by 41 and 37 per cent, respectively, in comparison with the 12 mm recommended shell thickness.

Modeling of Dimensional Accuracy in Three Dimensional Printing for Light Alloy Casting

2014 ◽  
Vol 808 ◽  
pp. 65-78
Author(s):  
Rajesh Kumar ◽  
Rupinder Singh ◽  
Inderpreet Singh Ahuja
Keyword(s):  
Wall Thickness ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Outer Diameter ◽  
Shell Wall ◽  
Light Alloy ◽  
Three Dimensional Printing ◽  
Measuring Machine ◽  
Dimensional Printing ◽  
Shell Wall Thickness

The purpose of this paper is to develop mathematical model to investigate the influence of shell casting parameters. Three input parameters such as shell wall thickness (SWT), Pouring temperature (PT) and weight density (WD) were selected to give output in the form of average outer diameter (AOD) as dimensional accuracy. After identification of component, technological prototypes were produced. In this work three dimensional printing (3DP) has been used as rapid shell casting to make shell mould by using Zcast 501 powder with different shell wall thickness for six different light alloy materials. Measurements on a coordinate-measuring machine helped in calculating the dimensional tolerances of the castings produced. For obtaining tight casting tolerances the dimensional accuracy of component is the most important element. The thickness, curing time and orientation of the shell molds, play an important role in providing a high quality of the cast part in time. The dimensional accuracy was found to be more in the case of maximum layer thickness and horizontal position of the component. The investigation has led to conclusions as the Quadratic models were developed for the response. The F - value is 23.93, which implies that the model as well as lack of fit is significant. The value of Prob > F is less then the standard value 0.05, which indicates model terms are significant. With the help of Post curing, shell Mold temperature was not found to affect the dimensional accuracy of the castings, significantly. It was observed that high pouring temperatures also produced castings with better dimensional accuracy. This study will provide main effect of the inputs on average outer diameter as dimensional accuracy in three dimensional printing of light alloys castings. Statistically in this case B, C, A2, B2, C2, AB, BC is the model terms which contributes significantly to the model developed for dimensional accuracy.

A three-dimensional shoulder protector based on ergonomics for workers

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ran-i Eom ◽  
Yejin Lee
Keyword(s):  
Body Shape ◽  
Three Dimensional ◽  
Health And Safety ◽  
The Body ◽  
Construction Sites ◽  
Content Type ◽  
Three Dimensional Printing ◽  
Functional Studies ◽  
Work Posture ◽  
Dimensional Printing

PurposeThe use of shoulder protectors is strongly recommended when carrying objects on the shoulder to ensure the health and safety of workers. Thus, this study aimed to develop and verify an ergonomic shoulder protector that considers human body shape and carrying posture from an ergonomic perspective. Ultimately, this study will present a shoulder protector with enhanced fit and safety for carrying workers at construction sites.Design/methodology/approachThe shoulder protector was designed and printed using three-dimensional printing technology with variable side neck points and shoulder point heights to reflect the human body's shoulder line shape and to position the carried object stably on the shoulder. The developed shoulder protectors were evaluated in terms of their fit according to the work posture of the carrier, adherence upon motion and durability through structural analysis.FindingsThe design of the shoulder protector for carrying workers followed the shoulder line. It is best placed above the side neck point by 1.0 cm and above the shoulder point by 2.0 cm. Its length is slightly shorter than the human shoulder for superior fit and safety.Originality/valueThe final shoulder protector (FSP) for carrying workers reflects the body curvature while enhancing fit and safety by considering activity and protective factors. As functional studies and evaluations on the need for protectors are scarce, this study provides fundamental data in the evaluation of protective gears.

Rapid manufacturing of copper-graphene composites using a novel rapid tooling technique

2020 ◽  
Vol 26 (4) ◽  
pp. 765-776 ◽  
Author(s):  
Gurminder Singh ◽  
Pulak Mohan Pandey
Keyword(s):  
Electrical Conductivity ◽  
Electrical Properties ◽  
Wear Rate ◽  
Coefficient Of Friction ◽  
Rate Coefficient ◽  
Three Dimensional ◽  
Rapid Tooling ◽  
Content Type ◽  
Three Dimensional Printing ◽  
Dimensional Printing

Purpose The purpose of this study is to study the mechanical, tribological and electrical properties of the copper-graphene (Cu-Gn) composites fabricated by a novel rapid tooling technique consist of three-dimensional printing and ultrasonic-assisted pressureless sintering (UAPS). Design/methodology/approach Four different Cu-Gn compositions with 0.25, 0.5, 1 and 1.5 per cent of graphene were fabricated using an amalgamation of three-dimensional printing and UAPS. The polymer 3d printed parts were used to prepare mould cavity and later the UAPS process was used to sinter Cu-Gn powder to acquire free-form shape. The density, hardness, wear rate, coefficient of friction and electrical conductivity were evaluated for the different compositions of graphene and compared with the pure copper. Besides, the comparison was performed with the conventional method. Findings Cu-Gn composites revealed excellent wear properties due to higher hardness, and the lubrication provided by the graphene. The electrical conductivity of the fabricated Cu-Gn composites started increasing initially but decreased afterwards with increasing the content of graphene. The UAPS fabricated composites outperformed the conventional method manufactured samples with better properties such as density, hardness, wear rate, coefficient of friction and electrical conductivity due to homogeneous mixing of metal particles and graphene. Originality/value The fabrication of Cu-Gn composite freeform shapes was found to be difficult using conventional methods. The novel technique using a combination of polymer three-dimensional printing and UAPS as rapid tooling was introduced for the fabrication of freeform shapes of Cu-Gn composites and mechanical, tribological and electrical properties were studied. The method can be used to fabricate optimized complex Cu-Gn structures with improved wear and electrical applications.

A review of 3D concrete printing systems and materials properties: current status and future research prospects

2018 ◽  
Vol 24 (4) ◽  
pp. 784-798 ◽  
Author(s):  
Suvash Chandra Paul ◽  
Gideon P.A.G. van Zijl ◽  
Ming Jen Tan ◽  
Ian Gibson
Keyword(s):  
Three Dimensional ◽  
Current Status ◽  
Future Research ◽  
Structural Elements ◽  
Construction Time ◽  
Content Type ◽  
Three Dimensional Printing ◽  
Materials Research ◽  
Printing System ◽  
Dimensional Printing

Purpose Three-dimensional printing of concrete (3DPC) has a potential for the rapid industrialization of the housing sector, with benefits of reduced construction time due to no formwork requirement, ease of construction of complex geometries, potential high construction quality and reduced waste. Required materials adaption for 3DPC is within reach, as concrete materials technology has reached the point where performance-based specification is possible by specialists. This paper aims to present an overview of the current status of 3DPC for construction, including existing printing methods and material properties required for robustness of 3DPC structures or structural elements. Design/methodology/approach This paper has presented an overview of three categories of 3DPC systems, namely, gantry, robotic and crane systems. Material compositions as well as fresh and hardened properties of mixes currently used for 3DPC have been elaborated. Findings This paper presents an overview of the state of the art of 3DPC systems and materials. Research needs, including reinforcement in the form of bars or fibres in the 3D printable cement-based materials, are also addressed. Originality/value The critical analysis of the 3D concrete printing system and materials described in this review paper is original.

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