Development of Rapid Prototyping Technique for Metallic Components

传统的金属铸件制造包括砂型的制备、铸造熔体、砂型的脱砂等工序，需要大量的人力和较长的生产时间。因此，需要减少人力和生产时间以及降低成本。许多研究人员已经研究了分层制造（或固体自由形状制造），以生产金属模具用塑料制成的原型。分层制造技术作为一种新型的金属零件近网制造技术，近年来受到了广泛的关注。在早期，快速成型方法已应用于塑料制品，其机械性能低，因此耐久性差。早在1995年，我们就开始在美国和德国开展工作，将熔融纺丝沉积法（FSD）作为RP技术的一种，应用于金属零件的加工和加工。在以往的工作中，研究了FSD法生产铝基和铜基合金铸件的圆柱形和矩形空心管和实心铸件的最佳形状控制条件，并建立了控制基本形状的工艺参数数据库，使铸件具有实际金属部件的基本形状，如金字塔形、酒杯形、结合基本形状控制参数，制作了活塞形状和涡轮叶片内通孔铸件。在本工作中，为了提高FSD方法对具有复杂三维形状的各种金属和合金铸件的可行性，对传统的FSD装置进行了一些改进。研究了由不同内外材料组成的双层管铸件的工艺参数和采用多喷嘴喷射系统的大型铸件的工艺参数。从所获得的结果中，获得了仪器部件和成形条件的基本知识和技术诀窍，包括制造各种合金铸件的工艺参数。少

Conventional manufacturing for metal castings consists of many processes such as the preparation of sand mold, casting the melt and the shake-out of the sand mold, which needs a lot of man-power and a long production time. Therefore, a reduction in man power and production time as well as a lowering in the cost has been requiredLayered manufacturing (or solid freeform fabrication) has been investigated by many researchers to produce a prototype made of plastics for metallic mold. Recently layered manufacturing method is called as rapid prototyping technique and has attracted considerable attention as a new nearnet manufacturing technology for metallic parts. In early stage, rapid prototyping method has been applied to plastic products, which have low mechanical properties and hence a poor endurance.In our earlier works, which started 1995 at the same time the works began in USA and Germany, a fused spinning deposition method(FSD) which is one of RP technologies, has applied to the fabr … More ication of metallic parts.In the previous works, the optimum conditions to control the shape of aluminum base and copper base alloy castings produced by FSD method have been investigated for the cylindrical and rectangular shaped hollow tube and solid castings In addition, the data-base for the process parameters to control fundamental shapes has been constructed and castings having a fundamental shape of the practical metallic components, such as pyramid shape,, wine glass shape, piston shape and castings with the inside through-holes like turbine-blade have been fabricated as application by combining the fundamental shape control parameters.In the present work, in order to promote the feasibility of FSD method to various metal and alloy castings having a complex 3D shape, some modification was performed to a conventional FSD apparatus. The process parameters to obtain a double layered tube castings consisting of different inner and outer materials and a large scale casting using a multi -nozzles injection system have been examined. From the results obtained, a fundamental knowledge and know-how of apparatus components and of the shaping conditions including process parameters for the fabrication of various alloy castings has been obtained. Less