Modern Casting; Oct2004, Vol. 94 Issue 10, p23-26, 4p, 6 Color Photographs
RAPID prototyping, PRECISION casting, METAL castings, and PROTOTYPES
Discusses the advantages of rapid prototyping and investment casting to metalcasters and design engineers. Steps involved rapid prototyping; Remarks from Ray Sander, lead modeler at the Battelle Memorial Institute of Columbus, Ohio, on running concept parts during the design phase; Overview of the rapid prototyping made by casting facility Aristo Cast; Methods for investment casting.
ENGINEERING design, RAPID prototyping, MANUFACTURING processes, PRECISION casting, INJECTION molding of metals, SIMULATION methods & models, CHEMICAL molding, and LITHOGRAPHY
Abstract: A rapid wax injection tool of a gearbox shift fork was designed, simulated, and manufactured using rapid prototyping and rapid tooling technology to save time and cost of producing wax models used for the investment casting process. CAE simulation softwares, in particular, MoldFlow, are used to get wax injection moulding parameters such as filling parameters, temperature profiles, freeze time, speed, and pressure. The results of this research were compared with conventional wax model production methods. The criteria of such comparison were based upon parameters such as time, cost, and other related characteristics, which resulted in saving of 50% in time and 60% in cost. In this research, design, assembly, and wax injection operation of the wax tool took 10 days. Considering the fact that wax melting temperature is as low as 70°C and injection pressure of 0.5 MPa, the tool suffers no damage due to the thermal and pressure stresses, leading to the mass production of wax models. [Copyright &y& Elsevier]