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Abstract
The use of rapid prototyping technologies for the production of sacrificial sand moulds for the foundry industry has been previously researched, but with selective laser sintering as the main technology, and with different methods of processing and materials as critical variables. With the proliferation of 3D printers and the relatively easy and economical production of moulds with special sands supplied by Z-Corporation, it is time that direct metal casting through 3D printing is scientifically investigated. Knowledge of the influence of various process parameters on the quality of moulds and subsequent castings is essential in effectively employing direct metal casting in real-world applications. This paper presents results of experimental investigations carried out to establish the influences of critical factors, such as curing times and temperatures, on mechanical characteristics, such as strength and permeability, of sand moulds produced by 3D printing. The dimensional and surface qualities of castings produced using the casting grade aluminium, A356, and the effectiveness of various mould surface coatings, and causes of casting defects, are also investigated. Statistically-designed experiments are employed for the systematic analysis of the individual roles of direct metal casting parameters, as well as their combined effects.
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Notes on contributors
S Singamneni
Dr Sarat Singamneni received a PhD in Mechanical Engineering in 1996 from the Indian Institute of Technology, Kharagpur, India. His core area of expertise is in the application of numerical methods for the analysis of manufacturing processes. He has proficiency in design of experiments, machinability studies and software development for numerical solutions. Sarat currently works as a senior lecturer in Mechanical and Production Engineering, Faculty of Design and Creative Technologies, AUT University, Auckland, New Zealand. Current research interests are in machinability, numerical applications to process evaluation, CAD/CAM, and rapid prototyping and manufacturing.
N McKenna
Nicholas McKenna is a graduate Mechanical Engineer from Auckland University of Technology (AUT). He recently enrolled for a masters of Engineering at AUT and is interested in pursuing research in rapid manufacturing. He is also working at Fisher and Paykel Healthcare as part of the Product Surveillance team as a Student Surveillance Engineer. He wants to become a experienced professional engineer with a specialised background in the rapid casting and manufacturing areas. Other than this, Nick also likes sports and music.
O Diegel
Prof Olaf Diegel is both an educator and a practitioner of engineering product development with an excellent track record of developing innovative solutions to engineering problems. In his role at Auckland University of Technology (AUT), he is director of the Creative Industries Research Institute, an interdisciplinary institute that crosses over between Engineering, Art & Design, Computers and Communications. He is widely published in the areas of product development, project management, smart house technologies, mechatronics and predictive health systems. In his consulting practice, Olaf develops a wide range of products for New Zealand and international companies. Over the past 10 years he has developed over 40 commercialised new products, including innovative new theatre lighting products, security and marine products, and several home health monitoring products.
D Singh
Prof Darius Singh has over 15 years experience in executive management in manufacturing companies. He has a PhD in Mechanical Engineering and also holds an MBA in Technology Management. He has spent much of his career with Ford Motor Company’s Manufacturing Operations in NZ, and Ford’s Research and Advanced Engineering Division in Detroit, USA. He has published over 100 peer review papers in total, covering manufacturing, metal casting, product design and technology management. He is presently Director of I-cubed (Institute for Industrial Innovation) at Auckland University of Technology (AUT) in NZ. Darius has forged strong alliances between academia and industry in several countries including NZ, Australia, USA, Germany, China and India. In doing so, he has created and globally trademarked RD&DTM (Research, Development & Deployment — the new “R&D”). Darius is a Fellow of the NZ Institute of Management and serves on several international governing boards.
T Neitzert
Prof Thomas Neitzert started his career as an academic staff member of the University of Stuttgart, Germany, before joining the R&D departments of Mercedes-Benz AG in the same city. After immigrating to New Zealand and working for New Zealand Steel, he took up the position of Engineering Manager of Fisher & Paykel Appliances, being responsible for the development of laundry and later refrigeration products. He became the Foundation Professor of Engineering at the University of Waikato in Hamilton, New Zealand, and is now the Head of School of Engineering of Auckland University of Technology (AUT), New Zealand.
J St. George
Dr John D. St. George is currently a senior lecturer in the Department of Civil and Environmental Engineering, University of Auckland. His academic qualifications are a BSc degree in Mining Engineering from Imperial College, London, an MSc in Rock Mechanics and Excavation Engineering from Newcastle University, UK, and a PhD from Auckland University for research on probabilistic approaches to slope stability. Professional qualifications include Chartered Engineer (UK), Member of IMMM, Fellow AusIMM and Member of the International Society of Explosives Engineers. He has industrial experience in the minerals industry working in Africa and the UK, and teaching experience in the areas of rock mechanics, slope stability, environmental engineering and surveying. His research interests are in the permeability of coal in relation to stress changes due to desorption, the spontaneous combustion of coal and related heating effects, stability issues related to mineral extraction sites mainly subsidence and slope stability. He is also actively involved in consulting on a wide range of projects in slope stability, rock properties and subsidence.
A Roy Choudhury
Dr Asimava Roy Choudhury obtained his Bachelors degree in mechanical engineering from the Jadavpur University, India, and his Masters (machine tools engineering) and Doctorate degrees from the Indian Institute of Technology (IIT), Kharagpur, India. He is at present an Associate Professor in the Department of Mechanical engineering, IIT, Kharapgur. His interests include manufacturing, more specifically CNC, RP, conventional and non-conventional machining.
P Yarlagadda
Prof Prasad Yarlagadda is currently the Director of Smart Systems Research and Professor in the School of Engineering Systems, Queensland University of Technology (QUT), Brisbane. He possesses over 30 years of experience in the area of materials, manufacturing and infomechatronics.