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10
Response Competitiveness:
Rapid Tooling & Casting
2008 Prof. B. Ravi, Mechanical Engineering Department, Indian Institute of Technology Bombay.
S
Sample
l
Tool Manufacture
and Inspection
Tool
Quote
1
Design
Approval
T i l
Trial
Production
Final Tooling
MOLD
PATTERN
MOLD
CORE BOX
CORE
PATTERN
MOLD
Sand Casting
Investment
C ti
Casting
DIE
Permanent
Consumable
Tooling Materials
Materials
Soft p
plaster
Hard wood
Plastic plaster
Epoxy resin
Polyurethane resin
Aluminium alloy
Copper alloys
y cast iron
Grey
Low alloy steel
Life (usage)*
100 - 500
500 - 1,000
1,000 - 5,000
5,000 - 50,000
20,000 - 60,000
20 000 - 60,000
20,000
60 000
40,000 - 60,000
200,000
,
- 300,000
,
300,000 - 500,000
* For sand casting process
Epoxy resin
core box for trials
Rapid Manufacture
Characteristics:
Minimum number of steps
Minimum process time for each step
Minimum supervision requirement
Minimum iterations/trials for quality
Foundation technologies:
Courtesy: Kirloslar
Copeland, Karad
Di
Directt Manufacture
M
f t
CAD to part, for intricate shapes (single or multiple).
Technologies: - Rapid prototyping/ soft tooling/ hard tooling
+ Investment casting
Vi
Virtual
t lT
Trials
i l
Predicting and preventing casting defects by simulation
PART CAD
MODEL
RP
PATTERN
few
SAND
MOULD
RUBBER
MOULD
few
WAX
PATTERN
METAL
MOULD
many
METAL
POURING
Rapid Tooling
Too
ol Life (numb
ber of parts)
)
1000
100
10
Hard
Bridge
Using secondary processes
s ch as in
such
investment
estment casting
casting,
using RP model as master.
Soft
Direct
1
Indirect
2
Number of steps
3D modeling
Virtual slicing
Layer by layer
fabrication
S lid b
Solid-based
d
Sh t b
Sheet-based
d
Stereolithography
g p y
(STL)
Selective Laser
Sintering (SLS)
Laminated Object
j
Manufacturing (LOM)
Fused Deposition
M d li
Modeling
(FDM)
Laser Engineered
N t Sh
Net
Shaping
i
(LENS)
Shape
p Maker
Shape Deposition
Modeling (SDM)
3-Dimensional
Printing (3DP)
support structure
RP Model of Pattern
Courtesy: Thermojet
Shell-making
Pouring of Al
Cast Part
RP
Courtesy: Thermojet
Investment Casting
Benchmarking of Routes
Large number of direct and indirect routes for rapid tooling
Each
E h route differs
diff
iin terms off fidelity,
fid li
finish,
fi i h time
i
and
d cost
Systematic approach required to select the appropriate route.
SLA Q
QC
FDM
Thermojet
j
LOM
Rubber mold
Benchmarking of Routes
RP-based Tooling Routes:
-B
Benchmarking
h
ki
20 RT routes:
t
1/2/3 step,
t
for
f sand
d casting/IC/PIM.
ti /IC/PIM
- RT route capability database: accuracy, finish, time, cost.
- Route selection methodology.
SLA:PP(UV):S
Stereo Lithography
SLA 5000 (3D Systems Inc.)
Build volume: 508x508x584 mm
Layer Thickness: 0.10 mm
Material
Part
Liquid Photo-Polymers
(UV curable Resins)
Support part material itself
Characteristics
Tolerance
Roughness
Time
Cost
+/ 0.36 mm
+/6 m
4 hrs
Rs. 8548
SLA:PP(UV):H
Stereo Lithography
SLA 5000 (3D Systems Inc.)
Build volume: 508x508x584 mm
Layer Thickness: 0.10 mm
Material
Part
Liquid Photo-Polymers
(UV curable Resins)
Support part material itself
Characteristics
Tolerance
Roughness
Time
Cost
+/ 0.36 mm
+/6 m
2.5 hrs
Rs. 6628
FDM:ABS/PC/PPS:S/H
Fused Deposition Modelling
FDM Maxum (Stratasys, Inc.)
Build volume: 600x500x600 mm
Layer Thickness: 0.254 mm
Material
Part
ABS, Polycarbonate,
Polyphenylsulfone
Support Water soluble
Characteristics:
Tolerance
+/- 0.127 mm
+/
Roughness
20 m
Time
7 hrs
Cost
Rs. 7230
LOM:LP:S
Laminated Object Manufacturing
LOM 2030 H (Cubic Technologies)
Build volume: 813x559x508 mm
Layer Thickness: 0.20 mm
Material
Part
+/ 0.89 mm
+/5 m
6 hrs
Rs. 4503
OBJ:PP:S
ObJet (PolyJet Modeling)
Eden 500V (Objet geometries ltd.)
Build volume: 500x400x200 mm
Layer Thickness: 0.016 mm
p
Resolution 600 Dpi
Material
Part
Photo polymer resins
Support Gel like proprietary material
Characteristics
Tolerance
Roughness
Time
Cost
+/ 0.46 mm
+/15 m
7.16 hrs
Rs. 5700
TJP:WAX:S
ThermoJet Printer
ThermoJet (3D Systems Inc.)
Build volume: 250x190x200 mm
Layer Thickness: 0.042 mm
p
Resolution 300 x 400 x 600 Dpi
Material
Part
Wax, Thermoplastic material
Support Part material itself
Characteristics
Tolerance
Roughness
Time
Cost
+/ 0.36 mm
+/3 m
6 hrs
Rs. 3897
SD:PVC:S
SoliDimension 3D Printer
SD 300 (Solidimension Ltd.)
Build volume: 230x185x150 mm
Layer Thickness: 0.165 mm
Material
Part
Engineered Plastic
(Polyvinylchloride)
Support part material itself
Characteristics
Tolerance
Roughness
Time
Cost
+/ 0.25 mm
+/4 m
7.4 hrs
Rs. 1654
SLA:PP(UV):S/H-VC:RTV:S-MC:EP:S
1. Stereo Lithography
2. Vacuum casting with Silicone
3. Mass casting with Epoxy
Characteristics:
/ 0.23 mm
Tolerance
+/Roughness
same as RP Part
Time
30 hrs (typical)
Cost
Rs. 2100
Spray
p y Metal Tooling
g
Mold failed at 65KN clamping force.
Metal shell peeled off after 150 shots.
Core features pulled off after 70 shots
shots.
Courtesy: CMERI, Durgapur
Saddle
Tumour
Hip prosthesis
[Courtesy: Tata Memorial Hospital, Mumbai
Resection line
Tumour boundary
SUMMARY
Tooling lead time is a bottleneck in product development
Conventional route: machining: takes several weeks.
Rapid tooling can reduce lead time by 50% or more.
Types: direct (from RP), or indirect (RP+secondary process)
Issues: tool life (soft, bridge, hard), complexity, accuracy.
Techno-economic benchmarking to select the best route.
Future developments: better materials, speed, accuracy.