Investigations for a statistically controlled rapid casting solution of lead alloys using three-dimensional printing

Abstract

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.

Keywords

three-dimensional printing statistically controlled rapid casting lead alloys dimensional accuracy

Get full access to this article

View all access options for this article.

References

Sachs

E. M.

Haggerty

J. S.

Cima

M. J.

Wiliams

A. P.

, Three dimensional printing techniques (1994) United States Patent No. US 005340656.

Karapatis

N. P.

Griethuysen

J. P. S.

Glardon

, ‘Direct rapid tooling: A review of current research’ Prototyping J. 4 2 (1998): 77–89.

Bassoli

Gatto

Iuliano

Violante

M. G.

, ‘3D printing technique applied to rapid casting’ Rapid Prototyping J. 13 3 (2007): 148–155.

Bernard

Delplace

J. C.

Perry

Gabriel

, ‘Integration of CAD and rapid manufacturing for sand casting optimization’ Rapid Prototyping J. 5 (2003): 327–333.

Wang

Conley

J. G.

Stoll

H. W.

, ‘Rapid tooling for sand casting using laminated object manufacturing process’ Rapid Prototyping J. 5 3 (1999): 134–140.

Dimitrov

Schreve

de Beer

, ‘Advances in three dimensional printing - state of the art and future perspectives’ Rapid Prototyping J. 12 3 (2006): 136–147.

Radstok

, ‘Rapid tooling’ Rapid Prototyping J. 5 4 (1999): 164–168.

Dimitrov

Wijck

van de Beer

Dietrich

, ‘Development, evaluation and selection of rapid tooling process chains for sand casting of functional prototypes’ J. Eng. Manuf. 221 B9 (2007): 1441–1450.

Verma

, Investigations for reducing wall thickness in aluminium shell casting using 3DP (2008): 27–57 M. Tech. Thesis, P.T.U. Jalandhar, India.

10.

UNI EN 20286-1. ISO (1995) ISO system of limits and fits. Bases of tolerances, deviations and fits.

11.

Kaplas

Singh

, ‘Experimental investigations for reducing wall thickness in zinc shell casting using three dimensional printing’ Proc. IMechE, Part C: J. Mechanical Engineering Science 222 C12 (2008): 2427–2431 DOI: 10.1243/09544062JMES1131.

12.

Devor

R. E.

Chang

Sutherland

J. W.

, Statistical quality design and control contemporary concepts and methods (New Jersey: Pearson Prentice Hall 2005): 78–91.