scholarly journals The Production of Plaster Molds with Patternless Process Technology

2015 ◽  
Vol 15 (2) ◽  
pp. 91-94 ◽  
Author(s):  
R. Pastirčák ◽  
A. Sládek ◽  
E. Kucharčíková
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Feed Rate ◽  
Manufacturing Process ◽  
Dimensional Accuracy ◽  
Mold Cavity ◽  
Drying Process ◽  
Process Technology ◽  
Batch Production ◽  
Gravity Casting

Abstract The work deals with technology Patternless process that combines 3 manufacturing process mold by using rapid prototyping technology, conventional sand formation and 3D milling. It's unconventional technology that has been developed to produce large-sized and heavyduty castings weighing up to several tons. It is used mainly in prototype and small batch production, because eliminating production of models. The work deals with the production of blocks for making molds of gypsum and gypsum drying process technology Thermomold. Into blocks, where were made cavities by milling were casted test castings from AlSi10MgMn alloy by gravity casting. At machining of the mold cavity was varied feed rate of tool of cemented carbide. Evaluated was the surface roughness of test castings, that was to 5 micrometers with feed from 900 to 1300 mm/min. The dimensional accuracy of castings was high at feed rate of 1000 and 1500 mm/min did not exceed 0.025 mm.

Precision rapid mould by transferred coating

2002 ◽  
Vol 216 (5) ◽  
pp. 753-759
Author(s):  
Z Shan ◽  
Y Yan ◽  
R Zhang ◽  
J Liang
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
Production Cost ◽  
Dimensional Accuracy ◽  
Rapid Tooling ◽  
Coating Materials ◽  
Production Cycles ◽  
Rt Process

The technique of precision rapid mould by transferred coating forming is an innovative rapid tooling (RT) process. It combines many techniques such as transferred coating and rapid prototyping. The main advantages of this process compared with other RT processes are low investment and production cost, shorter production cycles and many kinds of scale tool. The manufacturing process and the coating materials have been researched. The results of application show that net shape production may be fabricated in 2–7 days. The surface roughness of tools, Ra, can reach 1.6–6.3 äm, and dimensional accuracy may attain CT4-CT6.

Characterization of Cutting-Induced Heat Generation in Ultra-Precision Milling of Aluminium Alloy 6061

2013 ◽  
Vol 552 ◽  
pp. 201-206
Author(s):  
Su Juan Wang ◽  
Suet To ◽  
Xin Du Chen
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Heat Generation ◽  
Feed Rate ◽  
Dimensional Accuracy ◽  
Precision Machining ◽  
Machined Surface ◽  
Single Crystal Diamond ◽  
Ultra Precision ◽  
Alloy 6061

The technology of ultra-precision machining with single crystal diamond tool produces advanced components with higher dimensional accuracy and better surface quality. The cutting-induced heat results in high temperature and stress at the chip-tool and tool-workpiece interfaces therefore affects the materials and the cutting tool as well as the surface quality. In the ultra-precision machining of al6061, the cutting-induced heat generates precipitates on the machined surface and those precipitates induce imperfections on the machined surface. This paper uses the time-temperature-precipitation characteristics of aluminum alloy 6061 (al6061) to investigate the effect of feed rate on the cutting-induced heat generation in ultra-precision multi-axis milling process. The effect of feed rate and feed direction on the generation of precipitates and surface roughness in ultra-precision raster milling (UPRM) is studied. Experimental results show that heat generation in horizontal cutting is less than that in vertical cutting and a larger feed rate generates more heat on the machined workpiece. A smaller feed rate produces a better surface finish and under a larger feed rate, scratch marks are produced by the generated precipitates and increase surface roughness.

A Digital Near Net Shape Manufacturing Propeller with Complex Surface

2011 ◽  
Vol 201-203 ◽  
pp. 117-120
Author(s):  
Zhong Fei Jiao ◽  
Shan Yao ◽  
Shu Ming Zhao ◽  
Feng Zeng ◽  
Di Wu
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Complex Surface ◽  
High Accuracy ◽  
Parametric Modeling ◽  
Marine Propeller ◽  
3D Cad ◽  
Near Net Shape

An integrated digital routine is applied in the near net shape manufacturing of marine propeller. Firstly, the 3D CAD file of propeller is created by parametric modeling. Secondly, the propeller casting process is simulated using CAE software, through which an optimized casting scheme is obtained. Thirdly, fabricates the mold using laser rapid prototyping and cast the metal propeller. Finally, evaluate the casting precision performance. CAD, CAE and CAM are integrated in this process. The dimensional accuracy of the final piece is controlled within 1mm and its surface roughness achieves Ra 6.3μm. The result shows that the pattern-less casting of propeller can be achieved by this method, reducing cost and performing high accuracy.

Evaluation of Direct Rapid Prototyping Pattern for Investment Casting

2012 ◽  
Vol 463-464 ◽  
pp. 226-233 ◽  
Author(s):  
M.F.M. Omar ◽  
S. Sharif ◽  
M. Ibrahim ◽  
H. Hehsan ◽  
M.N.M. Busari ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Ceramic Powder ◽  
Dimensional Accuracy ◽  
Fused Deposition ◽  
Rp Process ◽  
Burn Out ◽  
Quality Assessments

The ability of rapid prototyping (RP) technology to fabricate direct part of any complex shape as a sacrificial pattern in shorter lead time has benefited the foundry industries significantly. The quality of investment casting (IC) parts is directly related to the master pattern fabricated from RP process. The main objective of this study was to evaluate the quality characteristics of various RP patterns that were fabricated by various RP processes which include 3D Printer (3DP), Fused Deposition Modeling (FDM) and Multijet Modeling (MJM). Evaluation of the RP patterns was carried out on dimensional accuracy, surface roughness and pattern shrinkage. Different internal pattern designs for the RP parts were developed using Insight software for FDM process and Solidworks 2011 for other RP systems. In addition to the quality assessments, the effect of the internal pattern designs on the burn out behaviour of the RP patterns was also evaluated. Experimental results showed that FDM and MJM produced patterns with better accuracy, surface roughness and part shrinkage when compared to 3DP. It was evident that the internal pattern structure improved the accuracy of the patterns produced from all RP processes. Results showed that FDM and MJM processes were superior in terms of mold cleanliness when no residual ash was observed during the burn out stage. Significant oxidation of ceramic powder was observed on the molds of the 3DP patterns which need to be removed manually from the molds.

scholarly journals Experimental Studying of the Variations of Surface Roughness and Dimensional Accuracy in Dry Hard Turning Operation

2018 ◽  
Vol 12 (1) ◽  
pp. 175-191 ◽  
Author(s):  
S. Yousefi ◽  
M. Zohoor
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Tool Wear ◽  
Feed Rate ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Dimensional Accuracy ◽  
Spindle Speed ◽  
Cutting Depth ◽  
Nose Radius

Objective: Hard turning in dry condition using cubic boron nitride tools, as an alternative of traditional grinding operation, is an advanced machining operation in which hardened steel with the hardness greater than 46 HRc is machined without the use of any coolant. Method: In the hard turning process, due to its hard nature, usually the cutting depth is selected lower than or equal to the nose radius, and the cutting zone is mainly limited within the tool nose area. Thus, unlike the traditional turning, the effect of the nose radius on the surface finish and dimensional accuracy becomes more complicated. Therefore, in this paper, firstly, the effect of processing parameters such as nose radius on the surface roughness and dimensional accuracy is investigated. Then, the relationship between the surface finish and dimensional accuracy variations with vibration, cutting forces, and tool wear is studied experimentally. The results revealed that feed rate is the most important factor influencing the surface roughness, whereas spindle speed and cutting depth are insignificant factors. On the other hand, cutting depth and spindle speed have the greatest effect on the dimensional accuracy, while nose radius has no significant effect. The vibration and wear analysis revealed that compared with the vibration, the tool wear has no considerable effect on the dimensional accuracy. It was also observed that the spindle speed has a contradictory effect on the surface roughness and dimensional accuracy. The best dimensional accuracy is obtained at 500 rpm, while the best surface quality is achieved at 2000 rpm. Result: The obtained results also showed that increasing the feed rate from a particular value not only leads to no significant changes in the surface roughness value but in some cases can also decrease the surface roughness. Conclusion: According to the analysis results, the lowest cutting depth, the moderate feed rate, and the speed lower than 1100 rpm provide the best dimensional accuracy. Compared with carbides and ceramics, cubic boron nitride tools produce a better surface roughness at both higher cutting depth and speed. 0.202 µm is the best surface roughness that was obtained at rε = 1.2 mm, N = 2000 rpm, f = 0.08 mm/rev, d = 0.5 mm which is comparable with the surface quality obtained by the conventional grinding operation.

scholarly journals The Effect of Machining on Surface Integrity of AISI 1018

2018 ◽  
Vol 13 (1) ◽  
Author(s):  
Carlos Diaz ◽  
Carlos Vila Pastor ◽  
César Ayabaca ◽  
Orlando Calle
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Chemical Composition ◽  
Surface Integrity ◽  
Feed Rate ◽  
Manufacturing Process ◽  
Scientific Method ◽  
Sustainable Manufacturing ◽  
Experimental Methodology ◽  
Metallographic Analysis

The present work studies the effects of the feed rate and depth cut in the surface roughness, microhardness, microstructure and mechanical properties of AISI 1018 steel. The scientific method is applied to an experimental methodology that allows the quantification of results through chemical composition tests, CAD processes / CAE / CAM, metallographic analysis and hardness measurements. The results obtained contrast the trend and influence of the study parameters, raise causes and favorable or unfavorable effects on the surface of machined steel within a sustainable manufacturing process.

Studies on Rapid Prototyping Pattern Using PLA Material and FDM Technique

2013 ◽  
Vol 465-466 ◽  
pp. 1070-1074 ◽  
Author(s):  
Mustaffa Ibrahim ◽  
M.N. Hafsa
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Fused Deposition Modeling ◽  
Hollow Structure ◽  
Dimensional Accuracy ◽  
Response Analysis ◽  
Fused Deposition ◽  
Pattern Structure ◽  
Master Pattern ◽  
Part Orientation

The development of Rapid Prototyping (RP) gave the consumer the ability to form prototype or a component of the prototype that can be directly used in assemblies and product testing for short or medium production with the least time consumed. The purpose of this paper is to study the dimensional accuracy and surface roughness for RP part as a master pattern for Investment Casting (IC) process. The material that been used is Polylactic acid (PLA) using a technique of Fused Deposition Modeling (FDM). The effects of internal pattern structure and part orientation during fabrication on the part master pattern can analyze from the response analysis. Results shows that PLA/FDM produced better accuracy and surface roughness when the part is fabricated with internal pattern structure compare to hollow structure. The internal pattern structures improved the quality of part and capable to supporting the design so that less warping or shrink. Part that built with 90o part orientation produced better accuracy and surface roughness compare to 0o part orientation.

APPLYING THE ISF TECHNOLOGY TO PRODUCE THE CAR PART MODELS

2010 ◽  
Vol 13 (4) ◽  
pp. 91-98
Author(s):  
Tuan Dinh Phan ◽  
Binh Thien Nguyen ◽  
Dien Khanh Le ◽  
Phuong Hoang Pham
Keyword(s):  
Rapid Prototyping ◽  
Incremental Sheet Forming ◽  
Cad Model ◽  
Post Processing ◽  
Technological Parameters ◽  
Batch Production ◽  
Complex Products ◽  
3D Cad ◽  
Real Size ◽  
Single Batch

The paper presents an application the research results previously done by group on the influence of technological parameters to the deformation angle and finish surface quality in order to choose technology parameters for the incremental sheet forming (ISF) process to produce products for the purpose of rapid prototyping or single-batch production, including all steps from design and process 3D CAD model, calculate and select the technological parameters, setting up manufacturing and the stage of post-processing. The samples formed successfully showed high applicability of this technology to practical work, the complex products with the real size can be produced in industries: automotive, motorcycle, civil...

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