ASSIGMENT - 7

Additive Manufacturing Influencing Metal Casting

SCHEMATIC OF IDEOLOGY

ABSTRACT

Additive Manufatuirng changing the way Industrial manufacturing works. In this study, an attempt has been made to bridge primitive additive manufacturing techniques and the age-old processes of Metal casting. This will be more cost-efficient and faster and flexible to add more designs.

ADDITIVE MANUFACTURING (AM)

The term “additive manufacturing” references technologies that grow three-dimensional objects one superfine layer at a time. Each successive layer bonds to the preceding layer of melted or partially melted material. It is possible to use different substances for layering material, including metal powder, thermoplastics, ceramics, composites, glass and even edibles like chocolate. Objects are digitally defined by computer-aided-design (CAD) software that is used to create .STL files. Gone are the intermediary steps, like the creation of moulds or dies, that cost time and money.

METAL CASTING

The casting is the backbone of the manufacturing industry. Metal casting is a complex and intricate process which requires exact chemistry and flawless execution.The basic workflow of metal casting involves pouring molten metal into the mould cavity that has dimensions with proper clearances for metal shrinkage due course of solidification. Generally, Iron, Aluminium, steel and copper-based alloys are cast, while a lot many metals can be casted, the process is sometimes limited by the high melting temperatures and the intricacies involved in the design. Parts weighing a few grams to those weighing a few tonnes can be casted and are done so, on a daily basis. Through the metal casting process, molten metal is poured into a mould that matches the final dimensions of the finished product. While all metals can be cast, the most predominant are iron, aluminium, steel and copper-based alloys. Castings range in weight from less than an ounce to single parts weighing several hundred tons.

TYPES OF CASTING

INTERVENTION OF 3D PRINTING

CASE STUDIES

FUTURE POSSIBILITIES

Additive manufacturing is a future. The process of 3D printing is already replacing conventional methods of casting, soon, 3D printing has the calibre to replace the process of casting itself. New types of 3D printing using innovative techniques are being experimented on every single day. Different types that are continuous printing, techniques for manufacturing the part on a heated conveyer belt. Not only the 3D printing techniques but also the materials that are being 3D printed have changed drastically, new materials that were never thought of before. In the casting industry itself, moulds made of PM (Powder metallurgy), Composites are being used but the research on those topics is fairly in the process as of now. When the applications of 3D printing are considered, they are ever-growing. These applications are limited to only by the imagination of the user not by the technology.

CONCLUSION

There is great potential in the incorporation of the antediluvian process of metal casting and contemporary additive manufacturing. Though, as studied above there are certain limitations of the integration but we can certainly say that the advantages surely outweigh them. The limitations are also not herculean to resolute, they can be resolved easily with a few uncomplicated steps. We can conclude from the various examples quoted that the parts casted from assistance of the additive manufacturing sciences have higher mechanical attributes, physical attributes, such as hardness, strength and surface finish. They are also less harmful to the environment as most 3D printed plastics are bio degradable and the fumes generated are also comparable to the conventional methods. It is also easier to manufacture patterns and moulds with 3D printing, with perfect geometric dimensioning and tolerances. The most important of all, at a fraction of the cost!

THE COMPLETE STUDY REPORT IS ENCLOSED - BRIEFS OF REPORT ARE PRESENTED IN WEBPAGE

REFERENCES