Download or read book Investigation Into Novel Runner Extension Designs for Sand Casting Utilizing 3D Sand Printing written by Ryan Stebbins and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Casting is one of the oldest manufacturing methods, dating to 5000 B.C. Its influence can still be seen today, accounting for a $110 billion impact on the US economy in 2019. Sand casting, is the most popular casting process due to its ability to produce relatively complex parts with almost any alloy at comparatively low costs, as well as manufacture both large components and small precision castings. Despite its prominence, casting has design limitations such as required draft angles and parting lines due to required tooling and patterns, which has led to the exploration of new manufacturing methods, such as additive manufacturing (AM). AM allows for increased part complexity, reduced material usage, part consolidation, usage of lattices, and decreased lead time between design and production. The rise of this novel technology is reflected in the large influx in publications and patents involving AM within in the past couple decades. However, its limitations in part size, cost, and available alloys prevent it from fully replacing casting. The merger of both sand casting and AM binder jetting into a hybrid manufacturing method is called 3D sand printing (3DSP), and it offers the benefits of both methods. With the advent of 3DSP, more complex geometries and castings are possible, allowing for the redesign and optimization of gating and rigging systems for defect reduction and improvements in casting quality. Despite research having already explored redesigning gating components like pouring basins, sprues, and runners using more complex mold geometries realizable through 3DSP, no research has considered the use of 3DSP for runner extensions. This thesis investigates various runner extension designs for the purpose of defect reduction. Out of the six different runner extension designs, three required 3DSP due to complexity. All designs were evaluated using simulation and experimental validation to ascertain their impact on casting quality. Designs were derived from literature review of gating system concepts. Simulations were completed using Flow-3D Cast v5 CFD software, comparing the resulting entrained air, tracer particles, and void particles present in the casting cavity. Results indicated difference between designs but required additional experimental comparisons to conclude runner extension impact. Designs were tested on manually poured Al319 cast plates, using a hybrid mold making method of both green sand and 3DSP extension molds. A total of eighteen plates were cast, three per design, all of which were scanned with computed tomography (CT) to determine the defect volume fraction present in the final castings. Three-point bending bars were machined from cast plates and tested to compare extension designs impact on mechanical properties. Statistical analysis of both mechanical performance and defect volume fraction showed no differences between runner extension designs. The results obtained in this thesis aid for the further optimization of gating systems and helping foundries reach zero defect casting.

Download or read book Investigation Into Non Conventional Mold Designs Using 3D Sand Printing in Castings written by Santosh Reddy Sama and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: In recent years, Additive Manufacturing (AM) technologies are fueling a paradigm shift in the advanced manufacturing landscape across all industrial sectors. The metal casting industry is also taking advantage of the wide variety of rapid manufacturing solutions offered by AM processes. The metal casting industry supports about 90% of total manufactured goods and is expected to reach a market size of about 40 billion USD by 2025. Sand casting is the most widely used metal casting process and utilizes expendable molds that demand expensive tooling, high lead time and limited flexibility in their fabrication. In addition, limitations in process control and feasible gating and feeding systems, traditional sand casting experiences higher scrap rates. AM offers an alternative mold fabrication technology known as 3D Sand-Printing (3DSP) process that enables direct digital manufacturing of complex expendable sand molds and cores without any tooling requirements. Ever-growing interest in this indirect metal AM process is attributed to its ability to rapidly produce cores and molds for complex metal castings that are otherwise impossible to manufacture using conventional techniques. Knowledge-based design rules for this process are currently very limited and are progressively realized in an ad-hoc basis to produce economic low-volume castings. Despite the wealth of knowledge in metal AM, no work to date has been reported to take advantage of design complexity offered by 3DSP in developing optimal gating and feeding designs to mitigate casting defects. This thesis provides the first known investigation into the application of design freedom offered by 3DSP to transform and monitor sand casting performance. Non-conventional design rules for gating and risering (also known as rigging) systems are developed to reduce surface turbulence, oxide films, air entrapment, bubble damage and several other casting defects, and improved metallic yield. Several case studies are presented to illustrate the improved casting performance through systematically reengineering elements of the rigging system viz. pouring basin, sprue, runners and risers. Their efficacy is validated through computational simulations and experimental procedures. Of the various components of gating system, innovative sprue design provides the highest opportunity to improve casting quality. Numerical models for novel parabolic and conical-helix sprue profiles can be developed through constrained optimization algorithm based on principles of casting hydrodynamics to reduce surface turbulence. Computational flow simulations, computed tomography scanning, microstructure and mechanical characterization experiments are performed to validate that incorporation of 3D Sand-Printing featured mathematically optimized gating systems (particularly conical-helix sprues) to significantly improve the performance of sand castings.Finally, existing foundry technologies have very limited capabilities to monitor real-time flow conditions of liquid metal during mold filling. Two approaches for novel non-intrusive real-time mold fill monitoring by embedding inexpensive miniature Internet of Things (IoT) sensors into 3d sand-printed molds are proposed. These sensor technologies are based on the electrical properties of molten metals, the former measuring the magnetic flux generated by the conductive liquid and the latter measuring the interference of electric fields by modifying dielectric near the sensor. Experiments are conducted to evaluate the efficacy of both these concepts. Results from experiments validate that IoT sensors can be embedded into 3DSP molds to successfully monitor flow fields that can be used to benchmark simulation results and optimize gating systems.

Download or read book A Study of Mixed Manufacturing Methods in Sand Casting Using 3D Sand Printing and FDM Pattern making Based on Cost and Time written by Ram A. Gullapalli and published by . This book was released on 2016 with total page 156 pages. Available in PDF, EPUB and Kindle. Book excerpt: Sand casting has long been known to be an effective manufacturing method for metal casting and especially for parts of large dimensions and low production volume. But, for increasing complexity, the conventional sand casting process does have its limitations; one of them mainly being the high cost of tooling to create molds and cores. With the advent of additive manufacturing (AM), these limitations can be overcome by the use of a 3D sand printer which offers the unique advantage of geometric freedom. Previous research shows the cost benefits of 3D sand printing molds and cores when compared to traditional mold and core making methods. The line of research presented in this thesis introduces the idea of additive manufacturing at different stages of the sand casting process and investigates the decision-making process as well as the cost-based effects. This will enable foundries and manufacturers to integrate the use of AM machines more smoothly into their production process without the need for completely re-engineering the existing production system. A critical part of this thesis is the tooling cost estimation using a casting cost model that is significantly accurate to industry standard quotes. Based on these considerations, this thesis outlines three approaches for achieving this goal apart from traditional mold and core making methods. The first approach integrates 3D Printing at the pattern making level where the patterns and core-boxes are "printed" on an FDM printer. This eliminates the tooling costs associated with a traditional sand casting method. The second approach integrates 3D Printing at the core-making level by "mixing" traditional mold-making process and 3D sand printing process for core-making. The third approach, the 3D sand printer is used to create both the molds and the cores, thereby eliminating the need for traditional methods. An initial hypothesis is created which states that, for a given production volume, with increased complexity of the casting, additively manufacturing only the cores and conventionally manufacturing the molds is cost-feasible when compared to traditional manufacturing or 3D sand printing. It is finally concluded that the initial hypothesis is valid when part geometries are highly complex and production volumes range between medium to high. It is also concluded that a decision making tool based on the methodology provided can help determine a specific mixed manufacturing method for the manufacturer.

Download or read book Improving Sustainability of Sand casting Processes Via Novel 3D Mold Designs written by Md Moinuddin Shuvo and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: For the past few decades, additive manufacturing (AM) has revolutionized manufacturing industries with seven different process categories. While offering features that subtractive manufacturing lacks, AM has also facilitated the sand casting industry through the binder jetting process. 3D sand printing (3DSP) is a type of binder jetting that fabricates complex sand molds and cores layer upon layer without requiring pattern plates, core boxes, and flasks. While the traditional mold-making techniques lacked design freedom due to draft, parting lines, and pattern issues, 3DSP is free from these obligations and capable of making sand molds with complex shapes and intricate features incorporated within the mold. Based on the ad-hoc, knowledge-based, and steel alloy-dominated design rules, improper gating and feeding system design have always contributed to various casting defects and generated high scrap rates. Available gating and feeding system design features are structured upon the traditional mold-making process and do not consider the complex design freedom 3DSP offers. This dissertation is focused on studying different novel riser (feeder) shapes, riser neck, and vortex chambers (slag traps) in comparison with the benchmark design used in the industry in order to reduce shrinkage and slag/surface defects and utilize the design flexibility of 3DSP. Three different alloys- nickel aluminum bronze (NAB), low carbon steel (WCB/ASTM A216), and Aluminum alloy (A319), were studied, which accounted for different freezing ranges. Solidification modeling and experimental validations show up to 45% yield improvement. The results are discussed in terms of computational flow and solidification simulations. Experimental validation of the computational results includes statistical analysis, Ultrasonic testing (UT), computed tomography scanning (X-ray CT), and mechanical characterization of the cast parts. To the best of the author's knowledge, this is the first effort to develop a computational solidification and experimental validation-based framework to claim the design freedom provided by 3DSP in terms of casting's feeding mechanism.

Download or read book Bridging the Oldest and Newest Manufacturing Technologies written by Philip King and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal casting is an old but important manufacturing technology, with an estimated 90% of durable manufactured products containing a casting. While traditional metal casting has existed for thousands of years, it remains a complex process under controlled conditions that suffers from variable casting outcomes, where the same casting design can have on casting run be defect free, and another casting run that must be scrapped. This variability has long been considered unavoidable, and even acceptable by the metal casting community. However, this outlook is no longer feasible, as nations across the world try to improve sustainability and reduce energy consumption. This dissertation presents original research to improve the performance of sand casting, the most widely used metal casting process, so that the industry can improve its sustainability. Leveraging additive manufacturing (AM) via 3D sand-printing enables us to reimagine the design principles of 3D mold geometry to improve casting quality and reduce casting variation. In this research, 3D sprue geometries were systematically studied for the naval alloy nickel aluminum bronze (NAB). When compared to the straight sprue geometry traditionally used in industry, the optimized 3D sprue geometries increased the ultimate flexural strength by 28% with while also reducing the variation with statistical significance. In addition to 3D sprue geometries, this dissertation studied 3D runner geometries for both AM and traditional molds. The optimized 3D runner geometries improved casting consistency by reducing the variance of the ultimate flexural strength by a statistically significant 74%. To accelerate our understanding of melt filling in sand molds, this dissertation also investigated new process monitoring techniques that can be integrated with IoT sensors (internet-of-things) with the potential to rapidly identify defective castings. Computer vision tracked the melt head in the runner system of open molds to extract its velocity, while ultrasonic sensors provided a means to measure in-gate velocity that previously could not be measured. This novel process measured the liquid metal surface height as the mold filled and then calculated the in-gate velocity using the surface height data. Overall, the innovations presented in the dissertation have made original contributions to the science of 3D mold design via 3D sand-printing to improve casting performance and in-process monitoring capabilities.

Download or read book MouldMaking and Casting written by Nick Brooks and published by Crowood. This book was released on 2013-12-21 with total page 418 pages. Available in PDF, EPUB and Kindle. Book excerpt: Mouldmaking and Casting is a technical manual of the many techniques of this ancient craft and art form. With step-by-step illustrations, it explains the materials required and the processes involved to create reproductions of a range of pieces. The book covers traditional techniques as well as today's more advanced technical methods.

Download or read book Metal Casting Principles And Practice written by T V Ramana Rao and published by New Age International. This book was released on 2007 with total page 316 pages. Available in PDF, EPUB and Kindle. Book excerpt: In This Book, The Topics/Syllabus Adequately Cover Metal Casting Subject In The Courses Of Mechanical, Production And Metallurgy Branches For B.E., B.Tech. As Well As Production And Industrial Metallurgy For M.Tech.With His Direct Experience In Metal Casting Industry And Teaching Academics The Author Attempts To Bridge The Gap Existing Between Essential Theory In Books And Vital Practical Applications In Industry.It Contains All The Molding Processes Normally Used With Details Of Ingredient Testing,Different Stages Of Casting Production Essential Theory Of Gating And Risering, As Well Asfinishing, Inspection And Quality Control.Over 80 Line Sketches Facilitate Easy Understanding. Information Given Through Over 20 Tables Help Easy Comprehension, Comparison And Remembrance. Exhaustive Examples Of Specific Components Normally Made By Casting Process Help To Build Confidence When Entering Industry. Over 200 Technical Books And Research Papers Upto May 1996 Are Referred. Examples Of Working Computer Programs Given, Form The Basis For Modern Practice-Oriented Projects In Final Year.For Practising Engineers, Managers And Entrepreneurs, This Book Provides Useful Theory And Practical Aspects On Foundry Management. Exhaustive Treatment Of Critical Gating & Risering With Many Industry Examples, Practical Solutions To Melting Problems, Casting Defects Analysis Through Cause-Effect Diagrams Will Be Very Useful. Essential Information. On Energy Conservation And Environmental Pollution Control Is Also Given In The Last Chapter.

Download or read book Casting Design and Performance written by and published by ASM International. This book was released on 2009 with total page 271 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book METAL CASTING written by B. RAVI and published by PHI Learning Pvt. Ltd.. This book was released on 2005-01-01 with total page 166 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents a scientific approach to metal casting design and analysis supported by software tools. Unlike other books in metal casting focused only on the process know-how, this book uncovers the know-why as well. Besides serving the needs of students of mechanical, production and metallurgical engineering, this book is equally meant to benefit practicing engineers involved or interested in casting development, including product designers, toolmakers, foundry engineers, supply chain managers, engineering consultants, researchers, and software developers. The theory discussed in the book is applicable to all types of castings: ferrous and non-ferrous, produced in sand and metal moulds. By gaining a better understanding of the theory and logic involved through creating, analysing and optimizing virtual castings, the readers will learn how to: Design process-friendly cast products, leading to shorter development time Manufacture assured quality castings, leading to fewer rejections and 'surprises' Manage material and energy utilization, leading to higher yield and lower costs.

Download or read book White Space Is Not Your Enemy written by Kim Golombisky and published by CRC Press. This book was released on 2017-02-17 with total page 612 pages. Available in PDF, EPUB and Kindle. Book excerpt: White Space Is Not Your Enemy is a practical graphic design and layout guide that introduces concepts and practices necessary for producing effective visual communication across a variety of formats—from web to print. Sections on Gestalt theory, color theory, and WET layout are expanded to offer more in-depth content on those topics. This new edition features new covering current trends in web design—Mobile-first, UI/UX design, and web typography—and how they affect a designer’s approach to a project. The entire book will receive an update using new examples and images that show a more diverse set of graphics that go beyond print and web and focus on tablet, mobile and advertising designs.

Download or read book Complete Casting Handbook Metal Casting Processes Metallurgy Techniques and Design written by John Campbell and published by Butterworth-Heinemann. This book was released on 2017-11-13 with total page 1220 pages. Available in PDF, EPUB and Kindle. Book excerpt: Complete Casting Handbook is the result of a long-awaited update, consolidation and expansion of expert John Campbell s market-leading casting books into one essential resource for metallurgists and foundry professionals who design, specify or manufacture metal castings. The first single-volume guide to cover modern principles and processes in such breadth and depth whilst retaining a clear, practical focus, it includes: A logical, two-part structure, breaking the contents down into casting metallurgy and casting manufacture Established, must-have information, such as Campbell s 10 Rules for successful casting manufacture New chapters on filling system design, melting, molding, and controlled solidification techniques, plus extended coverage of a new approach to casting metallurgy Providing in-depth casting knowledge and process know-how, from the noteworthy career of an industry-leading authority, Complete Casting Handbook delivers the expert advice needed to help you make successful and profitable castings. Long-awaited update, consolidation and expansion of expert John Campbell s market-leading casting books into one essential handbook Separated into two parts, casting metallurgy and casting manufacture, with extended coverage of casting alloys and new chapters on filling system design, melting, moulding and controlled solidification techniques to compliment the renowned Campbell 10 Rules Delivers the expert advice that engineers need to make successful and profitable casting decisions "

Download or read book Machine Drawing written by K. L. Narayana and published by New Age International. This book was released on 2009-06-30 with total page 10 pages. Available in PDF, EPUB and Kindle. Book excerpt: About the Book: Written by three distinguished authors with ample academic and teaching experience, this textbook, meant for diploma and degree students of Mechanical Engineering as well as those preparing for AMIE examination, incorporates the latest st

Download or read book Sand Control in Well Construction and Operation written by Davorin Matanovic and published by Springer Science & Business Media. This book was released on 2012-02-21 with total page 205 pages. Available in PDF, EPUB and Kindle. Book excerpt: Produced sand causes a lot of problems. From that reasons sand production must be monitored and kept within acceptable limits. Sand control problems in wells result from improper completion techniques or changes in reservoir properties. The idea is to provide support to the formation to prevent movement under stresses resulting from fluid flow from reservoir to well bore. That means that sand control often result with reduced well production. Control of sand production is achieved by: reducing drag forces (the cheapest and most effective method), mechanical sand bridging (screens, gravel packs) and increasing of formation strength (chemical consolidation). For open hole completions or with un-cemented slotted liners/screens sand failure will occur and must be predicted. Main problem is plugging. To combat well failures due to plugging and sand breakthrough Water-Packing or Shunt-Packing are used.

Download or read book Casting Processes and Modelling of Metallic Materials written by Zak Abdallah and published by BoD – Books on Demand. This book was released on 2021-02-24 with total page 167 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book, Casting Processes and Modelling of Metallic Materials, explores the various casting and modelling activities related to metallic alloy systems. The book provides results of research work conducted by experts from all over the globe to add to the research community in the era of the casting process and modelling. The book was edited by two experts in the field of materials science and modelling, Dr. Abdallah and Dr. Aldoumani, whom both have several publications in peer-reviewed journals, worldwide conferences, and scientific books. The book introduces the casting processes and then discusses the various issues and possible solutions. Over the past years, various models have been proposed and utilized to predict the performance of castings. Some of these models proved to be accurate whereas others failed to predict the casting performance. The strength of any predictive tool depends on the employment of physically meaningful parameters that replicate the real-life conditions. This has been illustrated in the current book with such predictive models and finite element (FE) modelling to illustrate the behaviour of castings in real-life conditions.

Download or read book Foseco Non Ferrous Foundryman s Handbook written by John Brown and published by Butterworth-Heinemann. This book was released on 1999-09-17 with total page 313 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Non-Ferrous Foundryman's Handbook provides a practical reference book for all those concerned with dealing with aluminium, copper and magnesium casting alloys.International SI units are used throughout, but in almost all cases conversions to the more familiar Metric and Imperial units are given. Wherever possible, Casting Alloy Specifications include equivalent specifications for several countries as well as international specifications. Individual chapters cover the casting of all types of non-ferrous metals. For each group of alloys, specifications, and typical applications are described, together with details of melting practice, metal treatment and casting practice. Sand moulding materials, including green sand and chemically bonded sands are also included. Recently there have been many major technical developments including new sand binders, the adoption of metal filtration of castings and widespread use of computers for the optimisation of feeder design.

Download or read book Crime Scene Investigation written by National Institute of Justice (U.S.). Technical Working Group on Crime Scene Investigation and published by . This book was released on 2000 with total page 64 pages. Available in PDF, EPUB and Kindle. Book excerpt: This is a guide to recommended practices for crime scene investigation. The guide is presented in five major sections, with sub-sections as noted: (1) Arriving at the Scene: Initial Response/Prioritization of Efforts (receipt of information, safety procedures, emergency care, secure and control persons at the scene, boundaries, turn over control of the scene and brief investigator/s in charge, document actions and observations); (2) Preliminary Documentation and Evaluation of the Scene (scene assessment, "walk-through" and initial documentation); (3) Processing the Scene (team composition, contamination control, documentation and prioritize, collect, preserve, inventory, package, transport, and submit evidence); (4) Completing and Recording the Crime Scene Investigation (establish debriefing team, perform final survey, document the scene); and (5) Crime Scene Equipment (initial responding officers, investigator/evidence technician, evidence collection kits).

Download or read book Gravel Roads written by Ken Skorseth and published by . This book was released on 2000 with total page 112 pages. Available in PDF, EPUB and Kindle. Book excerpt: The purpose of this manual is to provide clear and helpful information for maintaining gravel roads. Very little technical help is available to small agencies that are responsible for managing these roads. Gravel road maintenance has traditionally been "more of an art than a science" and very few formal standards exist. This manual contains guidelines to help answer the questions that arise concerning gravel road maintenance such as: What is enough surface crown? What is too much? What causes corrugation? The information is as nontechnical as possible without sacrificing clear guidelines and instructions on how to do the job right.