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Design methodology for variable shell mould thickness and thermal conductivity additively manufactured

Design methodology for variable shell mould thickness and thermal conductivity additively... Additive manufacturing (AM) is said to be the fourth industrial revolution disrupting the manufacturing industry. A focus on the foundry industry’s need, more specifically the sand casting process, is done. The usage of additive manufacturing in this field necessitates a different mould design approach. Indeed, it is important to take advantage of AM and the advantages of casting. The fabrication methodology of the mould is binder jetting technique. The almost limitless design possibilities of additive manufacturing are applied to sand moulds for metal casting. A new methodology to optimise the design of sand moulds is proposed. This optimisation reduces the amount of sand to the minimal need, which corresponds to a shell. The shell is then parametrised to have a specific cooling rate. In this case, the cooling speed can vary via a modification of the coefficient of thermal conductivity and shell thickness. The cooling speed is correlated to the dendrite arm spacing, which determines the mechanical properties such as ultimate tensile strength and hardness. Simulations of the cooling support the mould design methodology. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Welding in the World Springer Journals

Design methodology for variable shell mould thickness and thermal conductivity additively manufactured

Néel, T.; Mognol, P.; Hascoët, J.
Welding in the World , Volume 62 (5) – May 30, 2018
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14 pages

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Publisher
Springer Journals
Copyright
Copyright © 2018 by International Institute of Welding
Subject
Materials Science; Metallic Materials; Continuum Mechanics and Mechanics of Materials; Theoretical and Applied Mechanics
ISSN
0043-2288
eISSN
1878-6669
DOI
10.1007/s40194-018-0598-2
Publisher site
See Article on Publisher Site

Abstract

Additive manufacturing (AM) is said to be the fourth industrial revolution disrupting the manufacturing industry. A focus on the foundry industry’s need, more specifically the sand casting process, is done. The usage of additive manufacturing in this field necessitates a different mould design approach. Indeed, it is important to take advantage of AM and the advantages of casting. The fabrication methodology of the mould is binder jetting technique. The almost limitless design possibilities of additive manufacturing are applied to sand moulds for metal casting. A new methodology to optimise the design of sand moulds is proposed. This optimisation reduces the amount of sand to the minimal need, which corresponds to a shell. The shell is then parametrised to have a specific cooling rate. In this case, the cooling speed can vary via a modification of the coefficient of thermal conductivity and shell thickness. The cooling speed is correlated to the dendrite arm spacing, which determines the mechanical properties such as ultimate tensile strength and hardness. Simulations of the cooling support the mould design methodology.

Journal

Welding in the World – Springer Journals

Published: May 30, 2018

References

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    Ponche, R; Hascoët, J; Kerbrat, O; Mognol, P
  • Complex cast parts with rapid tooling: rapid manufacturing point of view
    Pessard, E; Mognol, P; Hascoët, JY; Gerometta, C
  • Investigation of optimum shell wall thickness of digitally produced shell moulds for brass casting using ZCast direct metal casting process
    Chhabra, M; Singh, R
  • Effects of moulding sands and wall thickness on microstructure and mechanical properties of Sr-modified A356 aluminum casting alloy
    Sun, SC; Yuan, B; Liu, MP
  • Towards zero waste in additive manufacturing: a case study investigating one pressurised rapid tooling mould to ensure resource efficiency
    Lušić, M; Barabanov, A; Morina, D; Feuerstein, F; Hornfeck, R
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    Dobrzański, LA; Król, M; Tański, T
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    Akhil, KT; Arul, S; Sellamuthu, R
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    Dobrzañski, LA; Maniara, R; Sokolowski, JH
  • Energy and material flow analysis of binder-jetting additive manufacturing processes
    Meteyer, S; Xu, X; Perry, N; Zhao, YF