The paper deals with the production technology of knee joint replacement by using rapid prototyping technology. The aim of the work is to outline the manufacturing technology intended for prototype production with the use of rapid prototyping and investment casting technology for use in orthopaedics and the surgery of knee joint replacement. The research results should make an effective contribution in the attempts to minimize the invasive surgical procedure, shorten the production of knee joint replacement as well as reduce the cost. At present, the research is focused on the preparation of STL data from CT (Computed Tomography) and verification of the production technology of prototypes made using available RP technology and its evaluation.
Based on Vacuum Differential Pressure Casting (VDPC) precision forming technology and the Selective Laser Sintering (SLS) Rapid Prototyping (RP) technology, a rapid manufacturing method called Rapid Precision Casting (RPC) process from computer three-dimensional solid models to metallic parts was investigated. The experimental results showed that the main advantage of RPC was not only its ability to cast higher internal quality and more accurate complex thin-walled aluminum alloy parts, but also the greatly-reduced lead time cycle from Selective Laser Sintering(SLS) plastic prototyping to metallic parts. The key forming technology of RPC for complex thin-walled metallic parts has been developed for new casting production and Rapid Tooling (RT), and it is possible to rapidly manufacture high-quality and accurate metallic parts by means of RP in foundry industry.
CA investment casting, rapid prototyping, solidification simulation, complex components, Technology, Manufactures, and TS1-2301
An integrative computer aided investment casting (CAIC) technology for making complicated superalloy castings was described. Key processes of CAIC were discussed including the choice of SLS (Selectively Laser Sintering) materials, sintering parameters, solidification simulation and gating and risering system optimization. Using CAIC process, many large-sized quality superalloy castings with complicated shape and thin wall have been produced successfully and economically in Central Iron & steel Research Institute (CISRI).
rapid prototyping, selected laser sintering, laser scanning, part accuracy, Technology, Manufactures, and TS1-2301
The effects of different factors, including the precision of the selected laser sintering (SLS) equipment, sintering temperature, sintered thickness of individual layer and laser scanning route, on the SLS part accuracy have been analyzed and studied. Some measures are suggested in order to improve the part accuracy made by SLS.
Virtual manufacturing based on through-process modelling becomes an evolving research area which aims at integrating diverse simulation tools to realize computer-aided design, analysis, prototyping and manufacturing. Numerical prediction of the as-cast microstructure is an initial and critical step in the whole through-process modelling chain for engineering components. A commercial software package with the capability of calculating important microstructure features for aluminium alloys is used to simulate a G-AlSi7MgCu0.5 laboratory casting. The simulated microstructure, namely grain size, secondary dendrite arm spacing and diverse phase fractions are verified experimentally. Correspondence and discrepancies are reported and discussed.
Up to now, so much casting analysis software has been continuing to develop the new access way to real casting processes. Those include the melt flow analysis, heat transfer analysis for solidification calculation, mechanical property predictions and microstructure predictions. These trials were successful to obtain the ideal results comparing with real situations, so that CAE technologies became inevitable to design or develop new casting processes. But for manufacturing fields, CAE technologies are not so frequently being used because of their difficulties in using the software or insufficient computing performances. To introduce CAE technologies to manufacturing field, the high performance analysis is essential to shorten the gap between product designing time and prototyping time. The software code optimization can be helpful, but it is not enough, because the codes developed by software experts are already optimized enough. As an alternative proposal for high performance computations, the parallel computation technologies are eagerly being applied to CAE technologies to make the analysis time shorter. In this research, SMP (Shared Memory Processing) and MPI (Message Passing Interface) (1) methods for parallelization were applied to commercial software "Z-Cast" to calculate the casting processes. In the code parallelizing processes, the network stabilization, core optimization were also carried out under Microsoft Windows platform and their performances and results were compared with those of normal linear analysis codes.