RP Process Selection for Rapid Tooling in Sand Casting

The significant cycle-time improvements and geometrical capabilities of solid freeform fabrication systems have led to applications in sand casting industry for design verification and tooling. The time and cost effective deployment of rapid tooling processes using rapid prototyping technology has thus becoming an emerging area to be studied. To make full use of the advantages of rapid prototyping processes, the factors influencing the tooling approach must be identified and understood. This understanding is then used to develop a decision-making structure for RP process selection for rapid tooling in sand casting. In this manuscript we review our work in evaluating and building a framework for tooling process selection for sand castingMechanical Engineerin

A weighted rough set based fuzzy axiomatic design approach for the selection of AM processes

Additive manufacturing (AM) or 3D printing, as an enabling technology for mass customization or personalization, has been developed rapidly in recent years. Various design tools, materials, machines and service bureaus can be found in the market. Clearly, the choices are abundant, but users can be easily confused as to which AM process they should use. This paper first reviews the existing multi-attribute decision-making methods for AM process selection and assesses their suitability with regard to two aspects, preference rating flexibility and performance evaluation objectivity. We propose that an approach that is capable of handling incomplete attribute information and objective assessment within inherent data has advantages over other approaches. Based on this proposition, this paper proposes a weighted preference graph method for personalized preference evaluation and a rough set based fuzzy axiomatic design approach for performance evaluation and the selection of appropriate AM processes. An example based on the previous research work of AM machine selection is given to validate its robustness for the priori articulation of AM process selection decision support

Benchmark pre-production practice in manufacturing engineering

Prototyping stage is a very important phase of new product development, where many decisions need to be taken to get high quality, zero defect products at the right time with minimum cost. Therefore, any value added improvements or best practices in the prototyping stage will support competitiveness of manufacturing companies. This research aims to benchmark the best practices in prototype part manufacture to support early stages of product introduction. A set of of best practices in the prototype component manufacture, along with validated four step prototyping strategy model and best practice prototype journey path model were developed. Research findings provide insight about prototyping trends, best practices and optimum ways of doing prototyping in the manufacturing companies around the globe. Manufacturing companies can use the developed models and best practices to make better prototype strategy in their new product introduction system to achieve their business objectives

Tool manufacturing by metal casting in sand moulds produced by additive manufacturing processes

Thesis (D. Tech. ( Mechanical Engineering )) - Central University of technology, Free State, 2012In this study an alternative indirect Rapid Tooling process is proposed. It essentially consists of producing sand moulds by Additive Manufacturing (AM) processes followed by casting of tools in the moulds. Various features of this tool making method have been investigated. A process chain for the proposed tool manufacturing method was conceptually developed. This process chain referred to as Rapid Casting for Tooling (RCT) is made up of five steps including Computer Aided Design (CAD) modeling, casting simulation, AM of moulds, metal casting and finishing operations. A validation stage is also provided to determine the suitability of the tool geometry and material for RCT. The theoretical assessment of the RCT process chain indicated that it has potential benefits such as short manufacturing time, low manufacturing cost and good quality of tools in terms of surface finish and dimensional accuracy. Focusing on the step of AM of the sand moulds, the selection of available AM processes between the Laser Sintering (LS) using an EOSINT S 700 machine and Three Dimensional Printing using a Z-Corporation Spectrum 550 printer was addressed by means of the Analytic Hierarchy Process (AHP). The criteria considered at this stage were manufacturing time, manufacturing cost, surface finish and dimensional accuracy. LS was found to be the most suitable for RCT compared to Three Dimensional Printing. The overall preferences for these two alternatives were respectively calculated at 73% and 27%. LS was then used as the default AM process of sand moulds in the present research work. A practical implementation of RCT to the manufacturing of foundry tooling used a case study provided by a local foundry. It consisted of the production of a sand casting pattern in cast iron for a high pressure moulding machine. The investigation confirmed the feasibility of RCT for producing foundry tools. In addition it demonstrated the crucial role of casting simulation in the prevention of casting defects and the prediction of tool properties. The challenges of RCT were found to be exogenous mainly related to workmanship. An assessment of RCT manufacturing time and cost was conducted using the case study above mentioned as well as an additional one dealing with the manufacturing of an aluminium die for the production of lost wax patterns. Durations and prices of RCT steps were carefully recorded and aggregated. The results indicated that the AM of moulds was the rate determining and cost driving step of RCT if procurement of technology was considered to be a sunk cost. Overall RCT was found to be faster but more expensive than machining and investment casting. Modern surface analyses and scanning techniques were used to assess the quality of RCT tools in terms of surface finish and dimensional accuracy. The best surface finish obtained for the cast dies had Ra and Rz respectively equal to 3.23 μm and 11.38 μm. In terms of dimensional accuracy, 82% of cast die points coincided with die Computer Aided Design (CAD) data which is within the typical tolerances of sand cast products. The investigation also showed that mould coating contributed slightly to the improvement of the cast tool surface finish. Finally this study also found that the additive manufacturing of the sand mould was the chief factor responsible for the loss of dimensional accuracy. Because of the above, it was concluded that light machining will always be required to improve the surface finish and the dimensional accuracy of cast tools. Durability was the last characteristic of RCT tools to be assessed. This property was empirically inferred from the mechanical properties and metallographic analysis of castings. Merit of durability figures of 0.048 to 0.152 were obtained for the cast tools. It was found that tools obtained from Direct Croning (DC) moulds have merit of durability figures three times higher than the tools produced from Z-Cast moulds thus a better resistance to abrasion wear of the former tools compared to the latter

AM Feature and Knowledge Based Process Planning for Additive Manufacturing in Multiple Parts Production Context

Additive Manufacturing (AM) has played an important role in manufacturing, especially in customized production. It is an ideal 'Concurrent Manufacturing' which enables fabricating a group of same or even different multiple parts simultaneously within one build volume due to its unique layer by layer processing way. However, there is very few available methods or tools for users, e.g. the AM manufacturing service bureaus, to optimize the process and production plan in multiple parts production context. To deal with this problem, this paper introduces an AM feature and knowledge based systematic process planning strategy. The main contents and key issues of process planning for AM in multiple parts production context are analyzed. Then, a developing CAPP system based on a systematic process planning framework for AM in this multiple parts production context is presented. Finally, some test examples are applied to demonstrate the functions and effectiveness of some key modules of the developing system.Mechanical Engineerin

The importance of a new product development (NPD) process: getting started.

In order to achieve a successful new product, and certainly the successful implementation of a new product into a company, it is necessary to have a structured and documented approach to New Product Development (NPD), therefore providing a clear roadmap for the development of new products. This review highlights the NPD process, from concept to consumer, and what the key success drivers are, such as; the quest for real product superiority and success, and the need for cross-functional teams; in order for a company to succeed and use new products as a source for competitive advantage