Design methodology for variable shell mould thickness and thermal conductivity additively manufactured
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Additive manufacturing (AM) is said to be the fourth industrial revolution disrupting the manufacturing industry. A focus on the foundry industry’s need, more specifically the sand casting process, is done. The usage of additive manufacturing in this field necessitates a different mould design approach. Indeed, it is important to take advantage of AM and the advantages of casting. The fabrication methodology of the mould is binder jetting technique. The almost limitless design possibilities of additive manufacturing are applied to sand moulds for metal casting. A new methodology to optimise the design of sand moulds is proposed. This optimisation reduces the amount of sand to the minimal need, which corresponds to a shell. The shell is then parametrised to have a specific cooling rate. In this case, the cooling speed can vary via a modification of the coefficient of thermal conductivity and shell thickness. The cooling speed is correlated to the dendrite arm spacing, which determines the mechanical properties such as ultimate tensile strength and hardness. Simulations of the cooling support the mould design methodology.
KeywordsAdditive manufacturing Casting Binder jetting Sand mould Optimisation DFAM
The authors would like to thank financial support from l’Agence Nationale de la Recherche (Grant, ANR-15-CE08-0037).
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