Comparison of Hybrid Rapid Mouldings for Zinc Alloy Castings

In this work comparison of hybrid rapid moulds (prepared with three dimensional printing shells supported with dry, green and molasses sand) have been made for techno-economic analysis, for zinc (Zn) alloy shell casting. The comparison has been made on the basis of mechanical properties and dimensional accuracy. Time-temperature curves have been drawn to understand solidification of molten Zn alloy in hybrid moulds of different thicknesses. The results of study suggest that it is feasible to reduce shell wall thickness of hybrid mould cavity from recommended 12mm to 1mm. All castings prepared are consistent with the permissible range of IT grades and are acceptable as per ISO standard UNI EN 20286-1 (1995). Further green sand based hybrid prototypes at 3mm shell wall thickness, shows better dimensional accuracy and mechanical properties.

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

Materials Science Forum ◽

10.4028/www.scientific.net/msf.808.65 ◽

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 ◽

Measuring Machine ◽

Dimensional Printing ◽

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.

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

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

10.1243/09544062jmes1131 ◽

2008 ◽

Vol 222 (12) ◽

pp. 2427-2431 ◽

Cited By ~ 14

Author(s):

M Kaplas ◽

R Singh

Keyword(s):

Mechanical Properties ◽

Shell Thickness ◽

Three Dimensional ◽

Dimensional Accuracy ◽

Zinc Alloy ◽

Experimental Investigations ◽

Economic Point ◽

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.

Effect of Moulding Sand Properties on Cost Effective Hybrid Rapid Casting Solution for Zinc Alloy

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1637 ◽

2011 ◽

Vol 264-265 ◽

pp. 1637-1642

Author(s):

Rupinder Singh ◽

T. Lal

Keyword(s):

Wall Thickness ◽

Cost Effective ◽

Zinc Alloy ◽

Shell Wall ◽

Rapid Casting ◽

Casting Solution ◽

Mould Cavity ◽

Measuring Machine ◽

Moulding Sand ◽

The purpose of the present experimental investigations is to study the effect of moulding sand properties on reducing the shell wall thickness of mould cavity for cost effective, hybrid rapid casting solution of zinc alloy. Starting from the identification of component/benchmark, technological prototypes were produced, with three different moulding sands (dry, green and molasses), at different shell wall thickness of mould cavity using hybrid rapid prototyping technique (combination of three dimensional printing and conventional sand casting). Measurements on the 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. The study suggested that for the shell thickness, having value less than the recommended one is more suitable from dimensional accuracy and economic point of view, for all three moulding sands. Further best shell wall thickness of the mould cavity for different moulding sands, for the selected component/benchmark has been highlighted for rapid casting solution of zinc alloy.

Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminium using Three Dimensional Printing

International Journal of Automotive and Mechanical Engineering ◽

10.15282/ijame.6.2012.1.0055 ◽

2012 ◽

Vol 6 ◽

pp. 680-691 ◽

Cited By ~ 2

Author(s):

Rupinder Singh ◽

Rajinder Singh

Keyword(s):

Wall Thickness ◽

Three Dimensional ◽

Thickness Reduction ◽

Shell Wall ◽

Rapid Casting ◽

Dimensional Printing ◽

Study the effect of moulding sand properties for reducing shell wall thickness in zinc casting using three-dimensional printing

International Journal of Rapid Manufacturing ◽

10.1504/ijrapidm.2011.043458 ◽

2011 ◽

Vol 2 (3) ◽

pp. 178

Author(s):

Tarsem Lal ◽

Rupinder Singh

Keyword(s):

Wall Thickness ◽

Three Dimensional ◽

Shell Wall ◽

Moulding Sand ◽

Dimensional Printing ◽

Effective shell wall thickness of vertically aligned ZnO-ZnS core-shell nanorod arrays on visible photocatalytic and photo sensing properties

Applied Catalysis B Environmental ◽

10.1016/j.apcatb.2018.03.099 ◽

2018 ◽

Vol 237 ◽

pp. 128-139 ◽

Cited By ~ 42

Author(s):

Kugalur Shanmugam Ranjith ◽

Rutely Burgos Castillo ◽

Mika Sillanpaa ◽

Ramasamy Thangavelu Rajendra Kumar

Keyword(s):

Wall Thickness ◽

Core Shell ◽

Nanorod Arrays ◽

Shell Wall ◽

Sensing Properties ◽

Vertically Aligned ◽

A Bayesian Approach for Estimating the Thinning Corrosion Rate of Steel Heat Exchanger in Hydrodesulfurization Plants

Advances in Materials Science and Engineering ◽

10.1155/2018/4314139 ◽

2018 ◽

Vol 2018 ◽

pp. 1-13 ◽

Cited By ~ 1

Author(s):

J. C. Velázquez ◽

F. Caleyo ◽

R. Cabrera-Sierra ◽

G. Teran ◽

E. Hernandez-Sanchez ◽

...

Keyword(s):

Wall Thickness ◽

Heat Exchangers ◽

Jet Fuel ◽

Statistical Techniques ◽

Shell Wall ◽

Oil Refineries ◽

Bayesian Data Analysis ◽

Thinning Rate ◽

Shell Wall Thickness ◽

Steel Heat

Fuel consumption has been increasing in recent years, especially that of diesel and jet fuel. For this reason, the necessity to build new plants to reduce their sulfur content has arisen. Sometimes, just revamping existing plants is feasible, but determining which pieces of equipment are in the appropriate condition to be reused is also necessary. In order to select the equipment, it is essential to have information about the wall thickness of vessels. Sometimes, the information is limited; consequently, the application of advanced statistical techniques is needed. The Bayesian Data Analysis (BDA) used in this study has the goal of determining a more accurate, unobserved thinning rate distribution for existing heat exchangers, taking into consideration all the information available about the thinning rate of the heat exchangers that cool down the effluent of the hydrotreating reactors in Mexican oil refineries. The information obtained from BDA was compared with existing shell wall thickness obtaining favorable results.