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.

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.

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.

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.

Experimental Investigations for Rapid Moulding Solution of Plastics Using Polyjet Printing

2011 ◽  
Vol 701 ◽  
pp. 15-20 ◽  
Author(s):  
Rupinder Singh ◽  
Varinderjit Singh
Keyword(s):  
Plastic Material ◽  
Coordinate Measuring Machine ◽  
Dimensional Accuracy ◽  
Point Of View ◽  
Experimental Investigations ◽  
Support Material ◽  
Economic Point ◽  
Measuring Machine ◽  
Plastic Components ◽  
Polyjet Printing

Rapid prototyping (RP) has been in evidence for the past twenty years and is being widely used in diverse areas, from the building of aesthetic and functional prototypes to the production of tools and moulds for technological prototypes. The purpose of the present study is to experimentally investigate the rapid moulding (RM) solutions for plastic components using polyjet printing (PP) technique. Starting from the identification of component/benchmark, prototypes with three different type of plastic material were produced, at different orientation and support material. Measurements on the coordinate measuring machine helped in calculating the dimensional tolerances of the plastic components produced. Some important mechanical properties were also compared to verify the suitability of the components. The study highlighted the best orientation, support material quantity and type of plastic material for the selected component from dimensional accuracy and economic point of view as RM solution for plastic components. This process ensures rapid production of pre-series technological prototypes and proof of concept at less production cost and time.

scholarly journals Plant-inspired pipettes

2018 ◽  
Vol 15 (140) ◽  
pp. 20170868 ◽  
Author(s):  
Keigo Nakamura ◽  
Tetsuya Hisanaga ◽  
Koichi Fujimoto ◽  
Keiji Nakajima ◽  
Hirofumi Wada
Keyword(s):  
Three Dimensional ◽  
Maximum Size ◽  
Experimental Investigations ◽  
Marchantia Polymorpha ◽  
Water Droplets ◽  
Rigid Object ◽  
Three Dimensional Printing ◽  
Simple Scaling ◽  
Dimensional Printing ◽  
Printing Techniques

The female sex organ of the liverwort ( Marchantia polymorpha ) has a characteristic parasol-like form highly suitable for collecting water droplets containing sperm for fertilization. Motivated by this observation and using three-dimensional printing techniques, we develop a parasol-like rigid object that can grab, transport and release water droplets of a maximum size of about 1 cm. By combining experiments and scaling theory, we quantify the object's fundamental wetting and fluid dynamical properties. We construct a stability phase diagram and suggest that it is largely insensitive to properties of liquids such as surface tension and viscosity. A simple scaling argument is developed to explain the phase boundary. Our study provides basic design rules of a simple pipette-like device with bubble-free capture and drop of liquids, which can be used in laboratory settings and has applications within soft robotics. Through systematic experimental investigations, we suggest the optimal design criteria of the liverwort-inspired object to achieve maximal pipetting performance. We also provide, based on our scalable model experiments, a biological implication for the mechanistic advantage of this structure in liverwort reproduction.

Experimental Investigations for Statistically Controlled Rapid Moulding Solution of Plastics Using Polyjet Printing

2010 ◽  
Author(s):  
Rupinder Singh ◽  
Varinderjit Singh ◽  
Manohar Singh Saini
Keyword(s):  
Plastic Material ◽  
Coordinate Measuring Machine ◽  
Dimensional Accuracy ◽  
Point Of View ◽  
Experimental Investigations ◽  
Economic Point ◽  
The Past ◽  
Measuring Machine ◽  
Plastic Components ◽  
Polyjet Printing

Rapid prototyping (RP) has been in evidence for the past twenty years and is being widely used in diverse areas, from the building of aesthetic and functional prototypes to the production of tools and moulds for technological prototypes. The purpose of the present study is to experimentally investigate statistically controlled rapid moulding (RM) solutions for plastic components using polyjet printing (PP). Starting from the identification of component/benchmark, prototypes with three different type of plastic material were prepared, at different orientations. Measurements on the coordinate measuring machine helped in calculating the dimensional tolerances of the components prepared. Some important mechanical properties were also compared to verify the suitability of the components. The study highlighted the best orientation, support material quantity and type of plastic material for the selected component from dimensional accuracy and economic point of view as RM solution for plastic components. Final components prepared are acceptable as per ISO standard UNI EN 20286-I (1995). This process ensures rapid production of statistically controlled pre-series technological prototypes and proof of concept at less production cost and time.

scholarly journals Effect of Three-dimensional Printing with Nanotubes on Impact Resistance

2019 ◽  
Author(s):  
Anne Schmitz
Keyword(s):  
Mechanical Properties ◽  
Lower Limb ◽  
Impact Resistance ◽  
Three Dimensional ◽  
Three Dimensional Printing ◽  
Impact Tester ◽  
The Impact ◽  
Dimensional Printing ◽  
Pendulum Impact ◽  
Pendulum Impact Tester

Abstract The types of biomedical devices that can be three-dimensional printed (3DP) is limited by the mechanical properties of the resulting materials. As a result, much research has focused on adding carbon nanotubes (CNT) to these photocurable polymers to make them stronger. However, there is little to no data on how CNTs affect the impact resistance of these polymers, an important property when designing and manufacturing lower limb prosthetics. The objective of this study was to expand the use of 3DP to prosthetics by testing the hypothesis that adding CNTs to a stereolithographic (SLA) photocurable resin will result in a cured polymer with increased impact resistance. Twenty-six total specimens: 13 with nanotubes and 13 without nanotubes, were printed on a Form2 SLA printer. Once all the specimens were printed, washed, and cured, the impact resistance was quantified using a pendulum impact tester in a notched Izod configuration. Contrary to the hypothesis, the specimens with SWCNTs (0.312 ± 0.036 ft*lb/in) had a significantly lower impact resistance compared to the non-SWCNT specimens (0.364 ± 0.055 ft*lb/in), U = 34.0, p = 0.004. This decreased impact resistance may be due to voids in the printed polymer around the aggregated nanotubes. Thus, SLA polymers still do not have the impact strength needed to be used for a full lower limb prosthetic.

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