Development of Rapid Prototyping Technique for Metallic Components

传统的金属铸件制造包括砂型准备、熔体浇注、砂型摇出等多个工序，人力投入大，生产时间长。因此，需要减少人力和生产时间以及降低成本。分层制造(或固体自由形状制造)已被许多研究人员研究以生产用于金属模具的塑料原型。近年来，分层制造技术被称为快速成型技术，作为一种新型的金属零件近净制造技术，受到了广泛的关注。早期的快速成型技术主要应用于机械性能较差、耐久性能较差的塑料制品。在我们的前期工作中，我们从1995年开始，同时在美国和德国开始了这项工作。熔融旋转沉积方法是快速成型技术之一，已经应用于Fabr…在前人的工作中，针对圆柱形和矩形空心管和实心铸件，研究了用FSD方法生产铝基和铜基合金铸件的最佳形状控制条件。此外，还建立了控制基本形状的工艺参数数据库，并结合基本形状控制参数制造了具有实际金属部件的基本形状的铸件，如金字塔形、酒杯形、活塞形状和带有涡轮叶片等内部通孔的铸件。本文的工作主要包括以下几个方面：为了提高FSD方法应用于各种形状复杂的金属和合金铸件的可行性，对传统的FSD装置进行了改进。研究了由不同内外材料组成的双层管铸件和采用多喷嘴喷射系统的大型铸件的工艺参数。从获得的结果中，获得了设备部件和成形条件的基本知识和诀窍，包括制造各种合金铸件的工艺参数。较少

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