Case Studies on Integrating 3D Sand-Printing Technology into the Production Portfolio of a Sand-Casting Foundry
Case Studies on Integrating 3D Sand-Printing Technology into the Production Portfolio of a Sand-Casting Foundry
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DOI：
10.1007/s40962-019-00340-1
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发表时间：
2019-05
影响因子：
2.6
通讯作者：
S. R. Sama;Tony Badamo;G. Manogharan
中科院分区：
文献类型：
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作者：
S. R. Sama;Tony Badamo;G. Manogharan
美国各地的金属铸造厂越来越多地采用增材制造的最新发展，包括 3D 砂打印 (3DSP)，因为它具有制造模具和型芯的独特能力，而无需任何模具、型芯、型芯盒、砂箱等。这种快速模具制造的新方法可以加快工艺周期时间，减少收缩缺陷，提供零件整合、功能集成和定制，从而促进铸造行业的发展。本研究展示了 3DSP 技术的采用如何为专门制造叶轮、涡轮机壳体和其他采矿设备的传统黑色金属铸造厂做出贡献。提出了四个工业案例研究来说明通过 3DSP 带来的新机遇。这些案例研究验证了 3DSP 能够：(1) 通过允许以最佳方向进行铸造而无需硬工具要求来减少收缩率；(2) 通过更轻松地将多个零件嵌套到单个模具中，通过快速模具制造来减少交货时间；(3) 通过将 3DSP 与传统模具制造集成来允许混合成型；(4) 分别制造无工具的复杂铸件。这项研究的结果将帮助铸造厂重新思考他们的设计流程，从传统的图案绘制到通过 3DSP 的全新、激进的基于自由形状的设计流程。
Metal casting foundries all across USA are increasingly adopting the recent development in additive manufacturing including 3D sand printing (3DSP) due to its unique ability to fabricate molds and cores without any tooling requirement such as patterns, cores, core boxes, flasks among others. This new method of rapid mold fabrication can accelerate process cycle times, reduce shrinkage defects, offer part consolidation, functional integration and customization that could facilitate the growth of foundry industries. This study demonstrates how the adoption of 3DSP technology has contributed to a conventional ferrous metal casting foundry that specializes in manufacturing impellers, turbine housings and other mining equipment. Four industrial case studies are presented to illustrate novel opportunities via 3DSP. These case studies validate that 3DSP has the ability to (1) reduce shrinkage by allowing casting in optimal orientation without hard-tooling requirements, (2) reduce lead time through rapid mold fabrication by easier facilitation of nesting multiple parts into a single mold, (3) allow hybrid molding by integrating 3DSP with conventional mold making and (4) fabricate tooling-less complex castings, respectively. Findings from this study would help foundries rethink their design process from traditional pattern-drawing to a new and radical freeform-based design process via 3DSP.