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

2007 ◽  
Vol 221 (9) ◽  
pp. 1441-1450 ◽  
Author(s):  
D Dimitrov ◽  
W van Wijck ◽  
N de Beer ◽  
J Dietrich
Keyword(s):  
Three Dimensional ◽  
Rapid Tooling ◽  
Sand Casting ◽  
Printing Process ◽  
Three Dimensional Printing ◽  
Core Technology ◽  
Process Chains ◽  
Accuracy And Repeatability ◽  
Dimensional Printing ◽  
Selection Of

This paper discusses the results obtained from studies on different rapid tooling process chains for improved design and manufacture of foundry equipment for sand casting of prototypes in final material for functional and pre-production tests of vehicles, using the three-dimensional printing process as core technology. Subsequently, while considering aspects such as time, cost, quality (accuracy and surface roughness), and tool life, a framework for evaluation and selection of the most suitable process chain in accordance to specific requirements is presented. Apart from only using these process chains for prototype manufacturing, initial results from a study to apply one of these process chains in automated sand casting full production is also presented. This research builds on an in-depth characterization of the accuracy and repeatability of a three-dimensional printing process.

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.

scholarly journals Selection of compositions for additive technologies in construction

2019 ◽  
Vol 97 ◽  
pp. 06018 ◽  
Author(s):  
Anastasiia Sharanova ◽  
Maria Dmitrieva
Keyword(s):  
Digital Technology ◽  
Field Experiments ◽  
Scientific Literature ◽  
Technological Development ◽  
Three Dimensional ◽  
Three Dimensional Printing ◽  
Construction Methods ◽  
Main Components ◽  
Dimensional Printing ◽  
Selection Of

Three-dimensional printing is an innovative digital technology and is one of the most significant achievements in the industrial and technological development of modernity. Digital 3D technologies have reached a colossal level of development over a period of about half a century since their invention. Using 3D printing in the construction of low-rise buildings, it becomes possible to implement almost any ideas and achieve the best architectural expressiveness of objects. The aim of this work is to create cement-based compounds that can be used in additive construction methods. A review of the scientific literature on this topic was carried out, the main components of the mixture were identified, and a series of field experiments were conducted. According to the results of the work, the optimal composition for 3D construction printing was determined.

scholarly journals Fine Details Obtained by 3D Printing and Using Polymers

2018 ◽  
Vol 55 (4) ◽  
pp. 474-477
Author(s):  
Laurentiu Slatineanu ◽  
Oana Dodun ◽  
Gheorghe Nagit ◽  
Margareta Coteata ◽  
Gheorghe Bosoanca ◽  
...  
Keyword(s):  
3D Printing ◽  
Three Dimensional ◽  
Printing Process ◽  
Three Dimensional Printing ◽  
Manufacturing Method ◽  
Nozzle Orifice ◽  
Systemic Analysis ◽  
Dimensional Printing ◽  
Printing Techniques ◽  
Isosceles Triangles

The three-dimensional printing is a manufacturing method involving the addition of materials by using certain principles valid in printing techniques. There are various techniques of a three-dimensional printing method and the most of them could be applied inclusively to generate objects of polymers. The objective of the research presented in this paper was to analyze the capabilities of 3D printing process or equipment of generating fine details and to identify a way of evaluating these capabilities when using polyester PLA as filament material. The systemic analysis of the printing techniques which use a fused polymer filament deposition showed that there are some groups of factors able to affect the obtaining of fine details. An experimental research was designed in order to highlight the influence exerted by the diameter of the nozzle orifice and by the values of sharp angles of isosceles triangles on the heights of these triangles, thus obtaining an image concerning the possibilities of generating sharp edges by three-dimensional printing. To evaluate the capacity of the 3D printing process of obtaining thin walls, a spiral including linear segments with a decreasing thickness from 1 mm was also achieved on the test piece. By mathematical processing of the experimental results using a specialized software, empirical mathematical models were determined to evaluate the intensity of influences exerted by the two process input factors on the heights corresponding to isosceles triangles characterized by sharp angles.

scholarly journals OPTIMISATION OF A RESIN-COATED CHROMITE SAND FOR RAPID SAND CASTING APPLICATIONS

2021 ◽  
Vol 32 (3) ◽  
pp. 290-298
Author(s):  
Neo Tshabalala ◽  
Kasongo Nyembwe ◽  
Malan Van Tonder
Keyword(s):  
Three Dimensional ◽  
Chemical Properties ◽  
Cost Effective ◽  
Sand Casting ◽  
Raw Material ◽  
Silica Sand ◽  
Three Dimensional Printing ◽  
Physical And Chemical ◽  
Dimensional Printing ◽  
And Chemical Properties

Applications of three-dimensional printing (3DP) to sand casting have been well-established in the last two decades. The preferred raw material is silica (quartz) sand, as it is the most readily available and cost effective sand. However, silica sand as a refractory material has some technical limitations, including high thermal linear expansion, low refractoriness, and thermal conductivity. Therefore, it is not suitable for all castings. Other refractory sand types are available, including chromite sand, which is abundantly available in South Africa. Analysis of the physical and chemical properties of in-laboratory coating of a locally available chromite sand was conducted through known metal foundry tests that provide an understanding of the quality and suitability of the use of chromite sand as a potential substitute for silica material for rapid sand-casting applications. The results of this study will inform the industry about the optimisation of parameters for the manufacturing of a resin-coated chromite sand and its use in additive manufacturing using a Voxeljet VX 1000 printer.

Microscopic analysis on dimensional capability of fused filament fabrication three-dimensional printing process

2021 ◽  
pp. 009524432110472
Author(s):  
Ans Al Rashid ◽  
Sikandar Abdul Qadir ◽  
Muammer Koç
Keyword(s):  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Process Conditions ◽  
Fused Filament Fabrication ◽  
Three Dimensional Printing ◽  
Dimensional Measurement ◽  
Taguchi’S Design Of Experiments ◽  
Functional Components ◽  
Accuracy And Repeatability ◽  
Dimensional Printing

Fused Filament Fabrication (FFF) has been the most widely used three-dimensional printing (3DP) technology due to its cost-effectiveness, easy application, and material readiness. FFF, to date, has been used to fabricate polymer components for rapid prototyping and increasingly for some end-user applications. Thus, there is a pressing need to optimize 3DP process parameters for FFF materials to achieve higher dimensional accuracy, especially in functional components for final use applications. Therefore, to ensure desired geometries with reasonable accuracy, precise measurements are required to validate the FFF process’s dimensional capability under different process conditions. This study presents the dimensional measurement and statistical analysis to evaluate the effect of printing materials, speed, and layer heights on dimensional accuracy and repeatability of the commercial FFF process. A benchmark part model was designed with different external and internal features commonly used in manufacturing processes. Taguchi’s design of experiments (DOE) was employed to obtain the experiments scheme, followed by the 3DP, dimensional measurement, and analysis of 3DP samples. Results revealed polylactic acid (PLA) material provided better dimensional control in most of the features. Higher printing speeds and layer heights were found optimum for external features/protrusions, whereas lower-to-medium speeds and layer heights were more appropriate for the fabrication of internal features.

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