3DPrinting (also called additive manufacturing) (AM)) has many advantages in manufacturing, and its vigorous development has also brought many changes to traditional manufacturing processes. In recent years, the sand casting process has undergone tremendous changes, but sand casting companies will not.3DPrint and go bankrupt,AMAnd the traditional sand casting process can be a partner,AMAdding PTFE can make traditional sand casting technology faster, more cost-effective and more flexible.
Even if you join3DWhen printing, the sand casting process is still basically the same:
●Use a replica or pattern mold of the intended final version
●The model is placed in a two-part mold with cores to create internal channels during casting.
●The special molding sand is compacted in the sandbox or molding chamber and on the model surface.
●Key parts such as doors are still retained
3D The step that printing changes in this traditional process is how the molds and basic equipment are made.
△Subtractive manufacturing mode and additive manufacturing mode
Traditional manufacturing methods use subtractive manufacturing techniques such as metal or plastic.CNCMilling, the process of machining a piece of material into the desired shape using a machine tool to selectively remove unwanted materials. On the other hand,AM is a“From scratch“The process of adding only required materials layer by layer into the build volume or build platform. Additive manufacturing technology processes can produce parts from a variety of polymers, including standard thermoplastics, thermosets, filled and photopolymer resins, and even metals.
Compared to traditional manufacturing, it is recommended to use 3D Print the casting model:
● Reverse engineering of worn model equipment – When using additive manufacturing, the sand casting process becomes more precise, automated and repeatable.3DScanners are used to scan original parts or models of equipment. Can be used 3D CAD The software adjusts or completes the design file then proceeds according to the appropriate tolerances and shrinkage factors. 3D Print.
●When the alloy used for the casting design changes – when the alloy changes, the shrinkage also changes,3D Printing tools can be quickly replicated to correctly produce castings with the correct alloy removal, eliminating offsets and model damage.
●Fast delivery time——3D Printed models can be produced in just hours and days, which is a major advantage when prototyping or delivering a small batch of parts.
●Requires multiple iterations, constant adjustments or major model adjustments, compared to adjusting mold equipment for traditional manufacturingGUJATFiles are then reprinted faster, more cost-effectively and with greater automation.
●Smaller complex core castings – combination 3D Print polymer models and 3D Printing sand core 3D Applying the process can quickly produce castings, thereby reducing costs and time.
not everything3DThe printing technology is the same
3D The number and range of printing technologies are vast, including sand binder jetting./Metal, laser powder bed fusion,YEARS Lithographic printing, filament extrusion or pellet extrusion. Factors such as part geometry, pattern size, and material requirements should be considered when selecting the best technology for sand casting equipment. large format 3D The printer will meet larger size requirements for many sand casting models. For example, direct pellet feed type3DPrinting can use a wide range of materials, with faster deposition rates than filament.3Dprint higher10times. Additionally, the cost of granular materials is lower than that of wire materials.10times, making pellet extrusion a cost-effective alternative to subtractive technologies.
Although 3D The printing technology itself brings significant benefits to the casting process, but sand casting applications also have several advantages when additive and subtractive materials are combined in a hybrid platform. Each gender3DPrinting technology is not omnipotent and has its own limitations. However, only when well combined with subtractive manufacturing can each of them fully realize their advantages.
△PLA 3D printing
△ABS particle printing,0.4 nozzle mm,0. 2 mm layer
△Particle printing and ABS treatment
To illustrate the effectiveness of hybrid platforms in sand casting applications, we can look at a practical example.Supplier of industrial services and supplies (PSSI) It is hoped that additive manufacturing can be used to reduce the cost and time of manufacturing model equipment. Their goal was to reduce lead times and costs while maintaining the quality of the pattern sizes. 50%。
Take advantage of hybrid platforms,Titanparticle extrusion3Dprinter,PSSI Able to eliminate assembly and wood processing processes of typical wood formwork equipment. And CNC The machines are different,3D Titanium The printer does not require constant labor to operate the equipment, allowing for long manufacturing runs and shortening delivery times. 60% above, while reducing the total cost. In addition, the materials selected PETG Not only is it more durable than wood, but it also has equal processing properties during final post-processing. The result is a faster, less expensive, near-net solution, straight from the printer.
△Photo by Supplier of industrial services and supplies provide
△Pump and core box assembly model
In the process of introducing additive manufacturing technology into sand casting, there are several things to consider:
1.Reduce surface roughness of sand cast models:
●Consider using high-performance polymers such as glass or carbon fiber-filled polymers. ABS、PCnylon or lardthey have greater durability.
●Consider eliminating polyolefins (PP、PE) exterior, primer/Paints adhere well to most high-performance polymers and it is possible to design coatings specifically for the object being printed.
2.High speed mode:
● Where reasonable, print and assemble the model equipment into sections. This reduces the impact of printing problems and generates tools via multiple printers in parallel rather than serially.
●Always focused on additive manufacturing (DFAM) Designed to minimize material, print time, support and print defects such as the following45rules and design of the diploma.
●For high wear areas, the area can be stitched into the pattern and replaced if excessive wear occurs.
●Develop vigorouslyGUJATFunction.
●Design and produce molding equipment to ensure a seamless connection with additive manufacturing equipment.
By integrating additive manufacturing into the sand casting process, foundries and pattern shops become more agile and competitive, able to bring high-quality castings to market faster and at a lower price than traditional methods.
Source: Antarctic Bear
Daguang focuses on providing solutions such as precision CNC machining services (3-axis, 4-axis, 5-axis machining), CNC milling, 3D printing and rapid prototyping services.
