Abstract
Rapid casting gives the opportunity to develop a new casting in days, not in weeks or months. Evaporative Pattern Casting (EPC) process gives flexibility to produce complex geometries by integrating several parts in single casting. The lead-time and cost involved in designing and fabricating the metal tooling for Expanded Polystyrene (EPS) pattern making can be overcome by using the Segmented Object Manufacturing (SOM) machine. This hybrid system of pattern making is explored with all sub-systems and a complicated EPS pattern is produced by this Rapid Prototyping system. Conventional EPC process is more complicated due to coating development, vacuum assisted metal pouring and vibration system for filling the cavities by unbounded sand. In the present work, different mold-making processes are explored to avoid complications of conventional process. The Green sand, No-bake sand, and Plaster of Paris molds are prepared using Rapid Prototyped EPS pattern to produce the castings. The castings are characterized by comparing the surface roughness, dimensional accuracy, hardness, and surface morphology.
This is a preview of subscription content, log in via an institution.
Buying options
Tax calculation will be finalised at checkout
Purchases are for personal use only
Learn about institutional subscriptionsReferences
Jiang, W., Li, G., Fan, Z., Wang, L., Liu, F.: Investigation on the interface characteristics of Al/Mg bimetallic castings processed by lost foam casting. Metall. Mater. Trans. A 47(5), 2462–2470 (2016)
Monroe, R.M.: Expendable patterns casting. American Foundryman Society Inc., pp. 84 (1992)
Brooks, H., Aitchison, D.: A review of state-of-the-art large-sized foam cutting rapid prototyping and manufacturing technologies. Rapid Prototyp. J. 16(5), 318–327 (2010)
Hope, R.L., Jacobs, P.A., Roth, R.N.: Rapid prototyping with sloping surfaces. Rapid Prototyping Journal 3, 12–19 (1997)
Hamade, R.F., Zeineddine, F., Akle, B., Smaili, A.: Modelangelo: a subtractive 5-axis robotic arm for rapid prototyping. Robot. Comput. Integr. Manuf. 21, 133–144 (2005)
Broek, J.J., Horvath, I., de Smit, B., Lennings, A.F., Rusak, Z., Vergeest, J.S.M.: Free-form thick layer object manufacturing technology for large-sized physical models. Autom. Constr. 11, 335–47 (2002)
Chen, H.Z., Shan, Z.D., Dong, H.Z.: Research of foam pattern processing for lost foam casting. Appl. Mech. Mater. 331, 600–603 (2013)
Kumar, S., Kumar, P., Shan, H.S.: Density optimization of slurry of coating materialused in the EPC process through Taguchi’s parameter design approach. Mater. Manuf. Process. 23(7), 719–725 (2008)
Maruyama, T., Gou N., Mitsuyoshi T., Keisuke N.: Effect of coating thickness on the molten metal filling rate of cast iron in the evaporative pattern casting process. Int. J. Metalcast. 11(1), 77–83 (2017)
Emami, S.M., Divandari, M., Hajjari, E., Arabi, H.: Comparison between conventional and lost foam compound casting of Al/Mg light metals. Int. J. Cast Metals Res. 26(1), 43–50 (2013)
Bhagchandani R.K., Kapil S., Kamble P., Karunakaran K.P.: Investigation of ablation studies of EPS pattern produced by rapid prototyping. Virtual Phys. Prototyp. 13(4), 311–324 (2018)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Bhagchandani, R.K., Ghodke, R., Manivannan, R., Negi, S., Kapil, S., Karunakaran, K.P. (2020). Characterization of Rapid Foam Castings Produced by Different Mold Making Processes. In: Shunmugam, M., Kanthababu, M. (eds) Advances in Additive Manufacturing and Joining. Lecture Notes on Multidisciplinary Industrial Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-32-9433-2_14
Download citation
DOI: https://doi.org/10.1007/978-981-32-9433-2_14
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-32-9432-5
Online ISBN: 978-981-32-9433-2
eBook Packages: EngineeringEngineering (R0)