Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing

The purpose of the present work is to study the effect of workpiece volume on reducing the shell wall thickness in rapid shell casting based upon three-dimensional printing (3DP) technology, and to evaluate the dimensional accuracy and mechanical properties of aluminum (Al) castings obtained as per...

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Main Authors:	Singh, Rupinder, Singh, Rajinder
Format:	Article
Language:	English
Published:	Universiti Malaysia Pahang 2012
Subjects:	TS Manufactures TA Engineering (General). Civil engineering (General)
Online Access:	http://umpir.ump.edu.my/id/eprint/3486/ http://umpir.ump.edu.my/id/eprint/3486/ http://umpir.ump.edu.my/id/eprint/3486/1/1_Rupendan.pdf

id	ump-3486
recordtype	eprints
spelling	ump-34862015-03-03T08:01:28Z http://umpir.ump.edu.my/id/eprint/3486/ Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing Singh, Rupinder Singh, Rajinder TS Manufactures TA Engineering (General). Civil engineering (General) The purpose of the present work is to study the effect of workpiece volume on reducing the shell wall thickness in rapid shell casting based upon three-dimensional printing (3DP) technology, and to evaluate the dimensional accuracy and mechanical properties of aluminum (Al) castings obtained as per the ISO standard UNIEN 20286-I (1995). Starting from the identification of component/benchmark, castings of different volumes (corresponding to workpieces of ɸ60 mm, ɸ50 mm and ɸ40 mm) were produced with different shell wall thicknesses. Measurements on a coordinate measuring machine (CMM) allowed the calculation of the dimensional tolerances of the castings produced. Some important mechanical properties were also compared to verify the suitability of the castings. The research proved that having a shell wall thickness with a value less than that recommended (12 mm) is more suitable from a dimensional accuracy and economic point of view (irrespective of the workpiece volume within the given selected range). All the castings produced with different shell thicknesses are acceptable as per the ISO standard. The results of the study suggest that workpiece volume has an unnoticeable effect on reducing the shell wall thickness for the selected range of volumes of casting. Furthermore, the hardness of castings produced is almost same for all shell wall thicknesses, from 12 mm to 1 mm. The results are supported by cooling (time-temperature) curves, which show unnoticeable changes in the rate of heat transfer at different shell wall thicknesses. Keeping in mind the cost effectiveness of the process, one (1) mm shell wall thickness has been recommended for the production of castings. For a 1 mm shell wall thickness, the production cost and time are reduced by 67.38% and 44.87% (for ɸ60 mm workpieces), 64.51% and 44.62% (for ɸ50 mm workpieces), and 69.50% and 59.64% (for ɸ40 mm workpieces), respectively. Universiti Malaysia Pahang 2012 Article PeerReviewed application/pdf en http://umpir.ump.edu.my/id/eprint/3486/1/1_Rupendan.pdf Singh, Rupinder and Singh, Rajinder (2012) Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing. International Journal of Automotive and Mechanical Engineering (IJAME), 6 (Jul. pp. 680-691. ISSN 2229-8649 (Print); 2180-1606 (Online) http://ijame.ump.edu.my/images/Volume%206/1_Rupendan%20Sing.pdf
repository_type	Digital Repository
institution_category	Local University
institution	Universiti Malaysia Pahang
building	UMP Institutional Repository
collection	Online Access
language	English
topic	TS Manufactures TA Engineering (General). Civil engineering (General)
spellingShingle	TS Manufactures TA Engineering (General). Civil engineering (General) Singh, Rupinder Singh, Rajinder Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing
description	The purpose of the present work is to study the effect of workpiece volume on reducing the shell wall thickness in rapid shell casting based upon three-dimensional printing (3DP) technology, and to evaluate the dimensional accuracy and mechanical properties of aluminum (Al) castings obtained as per the ISO standard UNIEN 20286-I (1995). Starting from the identification of component/benchmark, castings of different volumes (corresponding to workpieces of ɸ60 mm, ɸ50 mm and ɸ40 mm) were produced with different shell wall thicknesses. Measurements on a coordinate measuring machine (CMM) allowed the calculation of the dimensional tolerances of the castings produced. Some important mechanical properties were also compared to verify the suitability of the castings. The research proved that having a shell wall thickness with a value less than that recommended (12 mm) is more suitable from a dimensional accuracy and economic point of view (irrespective of the workpiece volume within the given selected range). All the castings produced with different shell thicknesses are acceptable as per the ISO standard. The results of the study suggest that workpiece volume has an unnoticeable effect on reducing the shell wall thickness for the selected range of volumes of casting. Furthermore, the hardness of castings produced is almost same for all shell wall thicknesses, from 12 mm to 1 mm. The results are supported by cooling (time-temperature) curves, which show unnoticeable changes in the rate of heat transfer at different shell wall thicknesses. Keeping in mind the cost effectiveness of the process, one (1) mm shell wall thickness has been recommended for the production of castings. For a 1 mm shell wall thickness, the production cost and time are reduced by 67.38% and 44.87% (for ɸ60 mm workpieces), 64.51% and 44.62% (for ɸ50 mm workpieces), and 69.50% and 59.64% (for ɸ40 mm workpieces), respectively.
format	Article
author	Singh, Rupinder Singh, Rajinder
author_facet	Singh, Rupinder Singh, Rajinder
author_sort	Singh, Rupinder
title	Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing
title_short	Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing
title_full	Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing
title_fullStr	Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing
title_full_unstemmed	Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing
title_sort	effect of workpiece volume on shell wall thickness reduction in rapid casting of aluminum using three-dimensional printing
publisher	Universiti Malaysia Pahang
publishDate	2012
url	http://umpir.ump.edu.my/id/eprint/3486/ http://umpir.ump.edu.my/id/eprint/3486/ http://umpir.ump.edu.my/id/eprint/3486/1/1_Rupendan.pdf
first_indexed	2023-09-18T21:57:50Z
last_indexed	2023-09-18T21:57:50Z
_version_	1777414198460940288

Effect of Workpiece Volume on Shell Wall Thickness Reduction in Rapid Casting of Aluminum using Three-Dimensional Printing

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