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.

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.

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