Casting Tool Design and Computer-Aided Manufacturing

Designing a casting tool and choosing materials technology parameters calls for special requirements both for workpiece and tool side. After designing the technological steps and procedures I select the cutting tools. Industrial developments take priority in cloud system engineering. I used this system in the casting tool manufacturing process. It is not easy to make a comprehensive and detailed design following technological steps. The allowances and joints were made on the M2L CNC milling machine. The CAM program was made with EdgeCam software. Defining the casting parameters accurately is still a challenge, but in our major it is not the most important. For the future we are planning a most complicated casting tool.

REDESIGN N METAL CASTING TOOLS USING ANTHROPOMETRY AND QFD

The case in the metal casting process is when the metal is melted and then poured into a liquid metal reservoir and then poured into a pouring tool and then poured into a mold. In the process of pouring into the mold is still using manual equipment, namely by using wood which ends have a container such as a bucket ( bucket)) made of a mixture of white cement, brick fire sand and clay and the metal liquid pouring tool has a length of 1.5 cm, a weight of 5 kg with a diameter of 15 cm and a height of a container for liquid metal 20 cm does not include the load. If the pouring device filling with liquid metal, then the weight reaches ± 20 kg, with a weight of ± 20 kg the worker must pour the liquid continuously into the mold and at least each worker must go back and forth 6 times pouring metal liquid into a mold in a single combustion process. Based on the nordic body map questionnaire data as many as 8 workers felt pain in the shoulder and arm because the burden was born, resulting in workers often feel pain in the muscles of the arms and back. Because the wooden handle used to pour metal liquid is too slippery (exposed to sweat), so there is a need for improvement in activities. From the results of the above observations, it is necessary to design ideas for new work facilities. It expects to affect the improvements related to the position of the hand in the process of pouring liquid into the mold. Then the design idea needs to be done in the form of a casting tool that has been modified and can be used according to user needs and can be said to be ergonomic, safe, and comfortable. The method used in designing castings is quality function deployment and anthropometric techniques.

Development of a High Pressure Die Casting Tool for Partial Integration of Glass Fiber Structures

Due to the growing demand for lightweight solutions in a wide range of industries, the selection and combination of various materials is becoming more and more important. As a result, the need for suitable joining technologies is increasing along with it. Within the DFG research group "Schwarz-Silber" ("black-silver"), Fraunhofer IFAM is investigating so-called transitional structures in cooperation with the University of Bremen. In this process, glass fiber structures are integrated into aluminum by a high pressure die casting process. These structures are used for the electrochemical insulation between aluminum and carbon fiber textiles, which are connected by textile processes in a subsequent production step. A solid hybrid structure is finally achieved through a resin-impregnation process. The key challenges are the positioning, pre-tensioning and infiltration of the glass fiber structures within the high pressure die casting process. In order to meet these challenges, a customized die casting tool was developed within the project. With the aid of mold-filling simulations, the die system of the die casting tool was optimized to achieve better infiltration of the fiber bundles and to additionally support the position of the glass fibers in the casting process. After the design of the molding tool, the implementation was carried out in collaboration with a toolmaker. In subsequent, up-to-date investigations, the positioning and infiltration of different variants of glass fiber structures is evaluated. The results are compared with previous attempts to position and infiltrate the glass fiber structures to assess the effect of the optimized newly designed tool.

Measurement and Application of 3D Ear Images For Earphone Design

Detail anthropometric dimensions and a 3D shape of the outer-ear are applicable to design ear-related products such as an earphone. However, 3D scanning of the ear part is quite difficult due to a complex shape of the ear, also detailed ear dimensions which are needed to be measured for earphone design were not identified in previous studies. This study collected 3D scan images of the whole outer-ear from 100 Korean participants (50 females and 50 males) aged 20 to 59, then measured their detailed ear dimensions for earphone design. The pinna part was directly 3D scanned; and complex shape of the concha and acoustic canal parts were cast by applying an ear casting tool, then the cast was scanned in 3D. 13 ear dimensions were measured by applying an ear measurement system coded using Matlab. Both 3D ear scans and ear measurements were applied to design some earphone parts (earphone-head, ear-band, ear-tip) in this study.

Effect of the Technological Parameters on the Thermal Conditions of Die-Casting Tool

The heat balance of a casting cycle can be ensured in short times by the annealing of the die-casting tool, by which the well-constructed and well-functioned cooling system can enhance productivity. Incorrect cooling, however, can lead to heat unbalance in the die casting tool, thus causing the destruction of casting quality, reduction of the lifetime of die casting tool and irreversible production-reduction. Beside the theoretical examination of construction and function of cooling system, the evaluation of the effectively removed heat quantities has great importance. The paper presents an analysis of the function of the cooling system of a scraggy thin casting of AlSi9Cu3 alloy, in case of different cooling parameters. Based on the measured results of the inlet and outlet temperatures and the volume flow of the cooling agents, the heat quantities belonging to the cooling circles are determined and an optimization of the cooling system is proposed. The findings of the analysis can be utilized for the construction and optimum operation of die-casting cooling systems.

Determination of Residual Stresses After Laser Remelting of Flame Sprayed Fe-Ni-Co-Mo Coating

In this paper, the residual stresses on flat specimens, made from 12-nickel precipitation hardening maraging hot-working tool steel coated with Fe-Ni-Co-Mo and subsuquent laser remelted using Nd:YAG laser, were determined using the hole drilling method. In this newly proposed multi-step process for hot working tool steel reparation, the residual stresses are generated during each step by different physical mechanisms. The flame spraying is a highly productive technique to replace worn out material but with limited bonding to the substrate material. Subsequent laser remelting improves coating's bonding with substrate, coating's density and deoxidation to improve wear resistance, erosion and corrosion resistance of the flame sprayed coatings. After laser remelting, the tensile stresses in coatings slightly reduces or shifts into compressive which in turns improves the crack initiation resistance of the repaired surface of the thermomechanicaly loaded die casting tool.