Top > IJAT > Direct Fabrication of IC Sacrificial Patterns via Rapid Protot ...

single-au.php

IJAT Vol.6 No.5 pp. 570-575
doi: 10.20965/ijat.2012.p0570
(2012)

Paper:

Views over last 60 days: 869

Direct Fabrication of IC Sacrificial Patterns via Rapid Prototyping Approaches

Omar Mohd Faizan Marwah*, Safian Sharif**, and Mustaffa Ibrahim*

*Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia 86400 BatuPahat, Johor, Malaysia

**Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, 81300 Skudai, Johor, Malaysia

Received:
April 2, 2012
Accepted:
August 7, 2012
Published:
September 5, 2012
Creative Commons License
Keywords:
rapid prototyping, investment casting, rapid investment casting, multijet modeling, fused deposition modeling
Abstract
Patterns made from conventional wax materials in the Investment Casting (IC) process can easily be distorted, damaged, or broken in transportation or routine handling or due to exposure to heat. Alternatively, the strength and toughness of most Rapid Prototyping (RP) materials virtually eliminates this drawback due to their resistance to heat, humidity, and post curing. The current study is conducted to investigate the feasibility of using RP processes such as FDM and MJM to fabricate IC patterns from Acrylonitrile Butadine Styrene (ABS) and acrylate based materials respectively to be used directly in IC process. Evaluation of the effects of different internal pattern designs of the RP parts are conducted based on the thermal analysis approach and burnout properties of the RP patterns. Ceramic shell molds are fabricated on both RP patterns and subsequently placed in an oven which is gradually heated to 1000°C. The decomposition temperature and the residual ash of the RP pattern materials is determined and analyzed. Results show that the acrylate pattern ofMJMdecomposes rapidly compared to the ABS pattern from the FDM process. It is also observed that quasi and square hollow internal structures show better collapsibility or burnout properties, with no cracks, compared to cross pattern and cross hatch designs.
Cite this article as:
O. Marwah, S. Sharif, and M. Ibrahim, “Direct Fabrication of IC Sacrificial Patterns via Rapid Prototyping Approaches,” Int. J. Automation Technol., Vol.6 No.5, pp. 570-575, 2012.
Data files:
References
  1. [1] P. Y. Greenbaum and S. Khan, “Direct investment casting of rapid prototype parts: practical commercial experience,” Proc. of 2nd European Conf. on Rapid Prototyping, Nottingham, 15-16 July, pp. 77-93, 1993.
  2. [2] P. J. Bartolo, “Stereolithography Materials:Processes and Applications,” Springer Science, 2011.
  3. [3] I. Gibson, D. W. R, and B. Stucker, “Additive Manufacturing Technologies; Rapid Prototyping to direct digital manufacturing,” Springer, 2009.
  4. [4] R. Hague and P. M. Dickens, “Improvements in investment casting with stereolithography Patterns,” Proc. of the Institution of Mechanical Engineers, Part B: J. of Engineering Manufacture, Vol.1, Issue 11, p. 215, 2005.
  5. [5] R. Hague and G. D’Costa, “Structural design and resin drainage characteristics of QuickCast 2.0,” Rapid Prototyping J., Vol.7, pp. 66-72, 2001.
  6. [6] M. Chhabra and R. Singh, “Rapid casting solutions: a review,” Rapid Prototyping J., Vol.17, Issue 5, pp. 328-350, 2011.
  7. [7] S. Wang and A. G. Miranda, “A study of investment casting with plastic patterns, materials and manufacturing processes,” Vol.25, Issue 12, pp. 1482-1488, 2010.
  8. [8] J. C. Ferreira and A. Mateus, “A numerical and experimental study of fracture in RP stereolithography patterns and ceramic shells for investment casting,” J. of Materials Processing Technology, Vol.134, pp. 135-144, 2003.
  9. [9] R. J. Hague and P. M. Dickens, “Stresses created in ceramic shells using QuickCast models,” Proc. of the 5th Solid Freeform Fabrication Symposium, Universiti of Austin, pp. 242-252, 1995.
  10. [10] R. Hague and G. D’Costa, “Structural design and resin drainage characteristics of QuickCast 2.0,” Rapid Prototyping J., Vol.7, pp. 66-72, 2001.
  11. [11] Y. Norouzi and S. Rahmati, “A novel lattice structure for SL investment casting patterns,” Rapid Prototyping J., Vol.15, pp. 255-263, 2009.
  12. [12] A. F. Society, “Investment casting enters low-volume production market with rapid prototyping patterns,” Engineered Casting Solutions, Vol.7, pp. 43-44, 2005.
  13. [13] G. Tromans, “Developments in Rapid Casting,” Profesional Engineering Publishing, 2004.
  14. [14] W. S. W. Harun, S. Safian, and M. H. Idris, “Evaluation of ABS patterns produced from FDM for investment casting process,” WIT Trans. on Engineering Sciences, Vol.64, pp. 319-328, 2009.
  15. [15] W. S. W. Harun, S. Sharif, M. H. Idris, and K. Kadirgama, “Characteristic studies of collapsibility of ABS patterns produced from FDM for investment casting,” Materials Research Innovations, Vol.13, No.3, pp. 340-343(4), 2009.
  16. [16] C. W. Lee and C. K. Chua, “Rapid investment casting Direct and Indirect approaches via fused deposition modelling,” Int. J. of Advanced Manufacturing Technology, Vol.23, pp. 93-101, 2004.
  17. [17] Y. S. Yan, “Rapid Prototyping and Manufacturing Technology: Principle, Representative Technics, Applications, and Development Trends,” Tsinghua Science & Technology, Vol.14, pp. 1-12, 2009.

Creative Commons License  This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Apr. 22, 2024