CDS10 Response RTC
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Transcript of CDS10 Response RTC
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Casting Design and Simulation
10Response Competitiveness:
Rapid Tooling & Casting
• Need for rapid casting development
• Tooling routes for casting
• Rapid prototyping (1-step)• Rapid tooling (multi-step)
© 2008 Prof. B. Ravi, Mechanical Engineering Department, Indian Institute of Technology Bombay.
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Need for Rapid Casting Development
First Sample Casting
• For approval before regular production
• Main order often goes to the fastest supplier
•• Who pays for tooling costs if main order is not placed?
rototype ast ngs
• For new product development and testing purpose; time is critical!
, , , …
• Indian suppliers (foundries) take 3-6 months for prototype castings
• Foreign vendors (ex. ACTech) expensive: typically $20K per casting.
Replacement Parts
• For obsolete but workin roducts where inventor is infeasible
• Users from defence, vintage automobiles, large machine tools
• Starting point: broken/worn-out part; drawings may be unavailable
• Conventional route: high cost and delay.
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Conventional Casting Development
Avera e lead time for castin roduction 12 weeks
1 1 6 3 1
Tool Manufacture
and Inspection
amp e
Approval
Tool
Design
r a
Production
,Casting development time can be reduced by over 50%
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Tooling for Casting
(Intermediate Tooling) Final Tooling
Die Casting MOLD
PATTERN MOLD
an as ng
CORE BOX CORE
Investmentast ng
Permanent Consumable
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Conventional Tooling Production
• Tool Material:
Metal: cast iron, steel, aluminum.
Non-metal: wood, plastic.
Metal corebox and core
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Conventional Tooling Production
• Tool Manufacture:
Simple: Manual machining (lathe, milling, grinding)
Complex: CNC machining: multi-axis milling, EDM, HSM.
.
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Tooling Materials
*
• Soft plaster 100 - 500
Epoxy resin
core box for trials
• Hard wood 500 - 1,000
• Plastic plaster 1,000 - 5,000
• Epoxy resin 5,000 - 50,000
• Polyurethane resin 20,000 - 60,000
, - ,
• Copper alloys 40,000 - 60,000
• Gre cast iron 200 000 - 300 000
• Low alloy steel 300,000 - 500,000
*
Production core box
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Rapid Manufacture
Characteristics:
• Minimum number of steps
• Minimum process time for each step
• Minimum supervision requirement• Minimum iterations/trials for quality
Foundation technologies:
Courtesy: Kirloslar
Copeland, Karad
• rec anu ac ure
CAD to part, for intricate shapes (single or multiple).
-
+ Investment casting
• r ua r a s
Predicting and preventing casting defects by simulation
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Rapid Tooling for Casting
•
• Challenge: tooling development for intricate shapes.
single
RPPATTERN
PART CADMODEL
SANDMOULD
METALPOURING
few
few
MOULDPATTERN
METAL many
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Rapid Tooling
Rapid Tooling: Tooling fabricated using Rapid Prototypingsys ems, rec y or n rec y.
p a r t s 1000 Hard
b e
r o f
100 Bridge
( n u m
Using secondary processes
l L i f
e suc as nves men cas ng,
using RP model as master.
T o
Direct Indirect1
Number of steps
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Rapid Prototyping: Principle
or Free Form Fabrication
3D modeling Virtual slicing Layer by layer
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Rapid Prototyping Systems
qu - ase o - ase ee - ase
Stereolithography Selective Laser Laminated Object
(STL)
Fused Deposition
Sintering (SLS)
Laser Engineered
Manufacturing (LOM)
Sha e Makero e ng
Shape Deposition
e ap ng
3-Dimensional
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Rapid Prototyping: Complexity
• Overhanging features (undercuts)
can be produced in RP without any special tooling
but require a support structure during fabrication.
• Material
same: liquid, solid, powder
different: solid
• Support Removal
machining
dissolving / melting
loose owder - shake off
support structure
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Rapid Prototyping: Accuracy
Accuracy depends on:
• Errors in the model
missing elements (edges, facets)
• Model slicing (number)
Slice thickness (staircase effect) Adaptive slicing
Cross hatch / contour parallel
Coarse fine
Hybrid schemes
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Rapid Tooling – Sand Casting
CAD Model of Pattern RP Model of Pattern Metal Cast Part
Courtesy: Thermojet
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Rapid Tooling – Investment Casting
PU RP Pattern
Courtesy: EOS Cast Part
Shell-making Pouring of Al
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Rapid Tooling – Metal Molds
Courtesy: Thermojet
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Secondary Processes: Vacuum Casting
RP master part (or mould) can e conver e o mou or par
by secondary processes:
• Mass casting(Epoxy/PU)
• Vacuum casting
• Metal spraying
(Keltool, low m.p. metals)
• nves men cas ng.
Vacuum casting machine
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Benchmarking of Routes
• Large number of direct and indirect routes for rapid tooling • Eac route i ers in terms o i e ity, inis , time an cost
• Systematic approach required to select the appropriate route.
SLA QC FDM Thermojet LOM Rubber mold
Courtesy: Naval Dockyard, Mumbai
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Benchmarking of Routes
• RP-based Tooling Routes: - enc mar ng rou es: s ep, or san cas ng .
- RT route capability database: accuracy, finish, time, cost.
- Route selection methodology.
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SLA:PP UV):S
Stereo LithographySLA 5000 (3D Systems Inc.)
Layer Thickness: 0.10 mm
Material
Part Liquid Photo-Polymers(UV curable Resins)
Support part material itself
Characteristics
Tolerance + - 0.36 mm
Roughness 6 μm
Time 4 hrs
Cost Rs. 8548
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SLA:PP UV):H
Stereo LithographySLA 5000 (3D Systems Inc.)
Layer Thickness: 0.10 mm
Material
Part Liquid Photo-Polymers(UV curable Resins)
Support part material itself
Characteristics
Tolerance + - 0.36 mm
Roughness 6 μm
Time 2.5 hrs
Cost Rs. 6628
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FDM:ABS/PC/PPS:S/H
Fused Deposition ModellingFDM Maxum (Stratasys, Inc.)
Layer Thickness: 0.254 mm
Material
Part ABS, Polycarbonate,Polyphenylsulfone
Support Water soluble
Characteristics:Tolerance + - 0.127 mm
Roughness 20 μm
Time 7 hrs
Cost Rs. 7230
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OBJ:PP:S
ObJet (PolyJet Modeling)Eden 500V (Objet geometries ltd.)
Layer Thickness: 0.016 mm
Resolution 600 D i
MaterialPart Photo polymer resins
Support Gel like proprietary material
CharacteristicsTolerance + - 0.46 mm
Roughness 15 μm
Time 7.16 hrs
Cost Rs. 5700
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TJP:WAX:S
ThermoJet PrinterThermoJet® (3D Systems Inc.)
Layer Thickness: 0.042 mm
Resolution 300 x 400 x 600 D i
MaterialPart Wax, Thermoplastic material
Support Part material itself
CharacteristicsTolerance + - 0.36 mm
Roughness 3 μm
Time 6 hrs
Cost Rs. 3897
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SD:PVC:S
SoliDimension – 3D PrinterSD 300 (Solidimension Ltd.)
Layer Thickness: 0.165 mm
Material
Part Engineered Plastic(Polyvinylchloride)
Support part material itself
CharacteristicsTolerance + - 0.25 mm
Roughness 4 μm
Time 7.4 hrs
Cost Rs. 1654
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SLA:PP UV):S/H-VC:RTV:S-MC:EP:S
1. Stereo Lithography2. Vacuum casting with Silicone
3. Mass casting with Epoxy
Characteristics:
Tolerance + - 0.23 mm
Roughness same as RP Part
Time 30 hrs (typical)Cost Rs. 2100
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Rapid Manufacture- Metal moulds
Direct Metal Laser Sintering
Distortion ± 0.2-0.5 mm
Roughness 1.6-2.1 µm
. - .
S ra Metal Toolin
Mold failed at 65KN clamping force.
Metal shell peeled off after 150 shots.
.
Courtesy: CMERI, Durgapur
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Case Study: Separator body
• Separator body of hydraulic filter assembly of armoured vehicle
Courtesy: CQAE, Pune
• Original part broken, drawings not available, replacement needed.
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Case Study: Art object
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Case Study: Pendant jewellery
• 22 Feb 2006, 2 p.m.: Start of modelling on FreeForm system• 23 Feb 2006, 3 p.m.: STL file transferred to Viper RP system
• 24 Feb 2006, 4 p.m.: RP model used for investment casting.
Gold jewellery pieces
use n ou n a
circa 1st century AD
Fine Jewellery,
Mumbai]
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Example- Hip prosthesis
Pelvic bone part
fabricated on
Resection line
,fit-checked withmatching saddle
.
Tumour boundary [Courtesy: Sushrut Surgicals, Mumbai]
• Surgery performed on schedule,
successful (first time in India).
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SUMMARY
Conventional route: machining: takes several weeks.
Rapid tooling can reduce lead time by 50% or more.
Types: direct (from RP), or indirect (RP+secondary process)
Issues: tool life (soft, bridge, hard), complexity, accuracy.
Techno-economic benchmarking to select the best route.
Future developments: better materials, speed, accuracy.