E-MANUFACTURING ONE-OFF INTRICATE CASTINGS

USING RAPID PROTOTYPING TECHNOLOGY

D. K. PAL
Scientist ‘C’, DRDO, Naval College of Engineering,
INS Shivaji, Lonavla-410 402, India

Dr. B. RAVI
Associate Professor, Mechanical Engineering Department,
Indian Institute of Technology, Powai, Mumbai-400 076, India

L. S. BHARGAVA
Scientist ‘F’, DRDO, Naval College of Engineering,
INS Shivaji, Lonavla-410 402, India

E-mail: [email protected]
[email protected]

ABSTRACT

There is an industrial need for rapid manufacture of one-off intricate castings, for defense, vintage
equipment and medical prosthetics. This paper presents a systematic approach for this purpose, using a
combination of reverse engineering, solid modeling, rapid prototyping, rapid tooling and Internet
technologies. Rapid prototyping (RP) technology, involving automated fabrication of intricate shapes using
a layer-by-layer principle, has matured over the last decade. Two basic characteristics of RP make it
eminently suited to e-manufacturing: (1) the main input is a solid model of the part in a facetted format
stored in a STL file (generated by 3D scanning an existing part or by solid modeling), and (2) the
fabrication process is highly automated; no part-specific tooling is required. In practice, there are a large
number of combinations of RP and RT, besides a choice of materials and fabrication equipment. These
decisions greatly influence the quality of the parts (in terms of surface finish, dimensional accuracy, strength
and life) as well as the lead-time and cost. The paper also presents the experimental investigations to
demonstrate the methodology and benchmarking major RP/RT methods for casting application.

Key words: Casting, Solid Modeling, Reverse Engineering, Rapid Prototyping, Rapid Tooling, Internet.

1. INTRODUCTION

Advances in computer and communication technologies have led to globalization

and increased competition. This in turn has fuelled interest in new methodologies and
technologies to improve and accelerate product development. The most promising of these
is Rapid Manufacturing, a combination of Rapid Prototyping and Rapid Tooling
technologies.
 Rapid Prototyping (RP) involves automated fabrication of intricate shapes from
CAD data using a layer-by-layer principle. These “three dimensional printers” allow
designers to quickly create tangible prototypes of their designs, rather than just two-
dimensional pictures. Such models make excellent visual aids for communicating ideas
with co-workers or customers and can also be used for testing purposes. For example, an
aerospace engineer might mount a model airfoil in a wind tunnel to measure lift and drag
forces. While designers have always utilized prototypes, RP is now allowing them to be
made faster and less expensively.
At least six different rapid prototyping techniques are commercially available, each
with unique capabilities. These are: Stereolithography (SLA), Fused Deposition Modeling
(FDM), Laminated object Manufacturing (LOM), Selective Laser Sintering (SLS), Solid
Ground Curing (SGC) and Ink-Jet Printing (IJP). A software ‘slices’ the CAD model into
a number of thin layers (~0.1 mm), which are then built up one atop another. Rapid
prototyping is an additive process, combining layers of paper, wax, or plastic to create a
solid object. In contrast, most machining processes (milling, drilling, grinding, etc.) are
‘subtractive’ processes that remove material from a solid block. RP’s additive nature
allows it to create objects with complicated internal features that cannot be manufactured
by other means. Major limitations of RP include part volume (less than 0.125 m3), and part
materials (mainly polymers). Most prototypes require from three to seventy-two hours to
build, depending on the size and complexity of the object. Initial investment is very high.
For simple shaped metals parts required in large quantity, conventional manufacturing
techniques are usually more economical.

3 RAPID CASTING DEVELOPMENT

Development for one-off intricate castings involves the challenges of economic

viability, quick tooling development and producing defect-free casting in the first attempt.
These challenges can be overcome by making use of RP process for developing casting
patterns for sand as well as investment casting. While RP may seem slow, it is much faster
than the weeks or months required to manufacture the tooling by conventional machining
processes, especially for complex shapes.

The RP processes can be used for directly producing the casting patterns, referred
to as direct rapid tooling. The RP parts can also be used as masters for ‘soft tooling’
processes such as epoxy mass casting, PU face casting, metal spray and RTV molding
(Ashley, 1994; Dvorak, 1998; Chua et al). Thus, the combination of RP and soft tooling
methods can give indirect routes (Figure 1) for casting tooling development (Akarte and
Ravi, 2000). An example of a double step route is an ABS mold by FDM process,
converted into a pattern by PU face Casting. An example of a triple step route is an ABS
plastic pattern master created by FDM, then converted into an epoxy mold by mass casting
and finally converted into a production pattern by PU face casting. The different machine
models and materials available for each RP and RT process give a large number of
potential routes.

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 Figure 1: Alternate Tooling Routes for Sand Casting

Several researchers have explored rapid casting development using RP and RT.
Castings produced by LOM patterns were found to be well within the acceptable quality
range and gave 25% cost saving (Mueller and Kochen, 1999). In another investigation, it
was found that LOM tooling yielded about 50% saving in time and cost compared to
aluminum tooling (Wang et al, 1999). The pattern and core box produced for a valve body
directly from FDM process took 73% less time than conventional methods (Sushila et al,
1999). In a study, three alternative approaches (rapid pattern, rapid tooling and hybrid) for
making molds, all starting from Stereolithography process, were compared (Chua, et al,
1998). The RP models were used in investment casting to produce foundry tooling and
castings, saving time up to 60-80% and proving more cost effective than conventional
methods (Warner, 1997). In another investigation, using RP processes to produce the
investment casting pattern and ultimately cast metal parts (Dickens, 1995), it was found
that castings were generally less accurate than the RP model. The foundry experience in
producing the casting from RP pattern was the most significant factor. A similar study was
carried out by NASA to evaluate various RP techniques for fabricating the pattern for a
fuel pump housing (Spada, 2000). It was concluded that RP techniques are effective for
complex 3D patterns.

There is an industrial need for rapid manufacture of one-off intricate castings for
defense, vintage equipment and medical prosthetics. The RP and RT technologies provide
the solution, but are limited by the high costs of installation and maintenance. This can be
overcome by using web-based technologies, to create e-manufacturing systems. A number
of researchers have explored the application of Internet for engineering purposes (Tan,
1998). Most of them have mainly focused on faster and effective communications and on
virtual reality (Broll, 1997). Francis et al have proposed a methodology called Internet
manufacturing (IMAN) for the development of a distributed rapid prototyping system via
the Internet to form a framework of Internet Prototyping and manufacturing for the
support of effective product development (Francis, et al, 2001).

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 Internet

Client Software Customer Check

- STL Correction Customer Database
Part parameters
- Login Server Software
Quotation
- Quotation Automatic
Request Order + STL Quotation
- Ordering/ STL
forwarding Process Planning
Express
Carrier Part Fabrication
Transport
Planning Packing & Dispatching

CUSTOMER CARRIER RP FACILITATOR

Figure 2: One-Day and One-Off E-Manufacturing Concept using RP Technology for

Casting Development

4 E-MANUFACTURING OF CASTINGS

Two basic characteristics of RP make it eminently suited to e-manufacturing: (1)

the main input is a solid model of the part in a facetted format stored in a STL file
(generated by 3D scanning an existing part or by solid modeling), and (2) the fabrication
process is highly automated; no part-specific tooling is required (no cumbersome selection
of tools, setup, processing sequence, etc.). It is possible to model the part or tooling in one
location and get the part automatically fabricated in another location by sending the data
over Internet. Starting from the part drawing, it is now possible to produce a medium
complexity casting within a week using this approach. The first step will involve
converting the part drawing into a solid model and then into the pattern model. The last
step will involve using the pattern to produce the cast part. Both of these are well
established. The critical middle step of casting pattern development can be compressed by
web-enabling the RP/T route. The steps are described below.

1. Log on to the server of the RP company and forward the STL file of the pattern to
be manufactured.
2. The STL file is checked and errors (such as missing facets and dangling edges) if
any, are fixed.
3. Automatic generation of quotation depending on the pattern volume.
4. After the customer accepts the offer, process planning is automatically done
(slicing, scheduling, selection of process parameters, etc.).
5. Part manufacturing is done on the RP machine, followed by post processing and
then packing for delivery.

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 6. The invoice and related forms are generated automatically and forwarded by e-
mail to the express carrier company, who prepares all other forms and papers and
plans the transportation. The pattern is delivered to the customer.

5 CASE STUDY
An industrial component (impeller casting) was selected to demonstrate rapid
casting development. The pattern (Figure 3a) was reverse engineered using Renishaw
Cyclone Laser scanner for getting the Cloud of points (CoPs) (Figure 3b). Using the Laser
scan CoPs, CAD model (Figure 3c) was generated using Imageware surfacer software.
STL format of the CAD Data was used for generating FDM Pattern in ABS plastic
material (Figure 3d). The STL file was sent over Internet to an RP facility with an FDM
machine. This FDM pattern was used for making Aluminium sand casting (Figure 3e).
Five different patterns with Stereolithography (standard and Quickcast), Fused Deposition
Modeling, Thermojet and LOM processes were also fabricated. In addition, a silicone
rubber mold was created using the SLA RP part as master (Figure 4). The results of the
comparative study are summarized in Table 2.

e c

Figure 3: Development of One-off Casting Using a FDM RP Pattern

(a) Original Wooden Pattern, (b) Laser Scan CoPs Data Using Renishaw Cyclone Scanner,
(c) CAD Model Developed Using Imageware Surfacer Software, (d) FDM ABS Pattern,
(e) Al Casting Developed Using FDM Pattern

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 a b

c d

e f

Figure 4: Experimental studies on rapid pattern making

(a) FDM Polycarbonate pattern, (b) SLA pattern, (c) Stereolithography QuickCast pattern,
(d) Thermojet pattern, (e) LOM pattern, (f) Silicone rubber mold.

Table-2: RP pattern development using other processes

Object RP Pattern RP Material Used Time Layer- Organisation/ Place
Machine Taken Thick-
(Hrs) ness,
mm

a FDM Stratasys Polycarbonate 7 0.254 M/s Stratasys Inc.,

Polycarbonate FDM Titan Bangalore
pattern

b SLA pattern SLA 250/50 Epoxy Resin 4 0.1 GTRE, Bangalore

BARC, Mumbai

c Stereolithography SLA 250/50 Epoxy Resin 4 0.1 GTRE, Bangalore

QuickCast
pattern,

d Thermojet pattern Thermojet Wax 4 0.1 GTRE, Bangalore

e LOM pattern Helysis Paper 3

LOM
Machine

f Silicone rubber Vacuum Silicone Rubber N.A. -- GTRE, Bangalore

mold casting

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 6 CONCLUSION
Pattern development is the main bottleneck (in terms of time and cost) for
manufacturing one-off intricate castings, especially for replacement purposes. This can be
overcome by a combination of reverse engineering, RP/RT and web-based technologies.
The approach has been demonstrated by taking up an industrial case study of an impeller
casting pattern. The pattern was solid modeled based from the reverse engineering data.
The model was used to fabricate five different patterns with Fused Deposition Modeling,
Stereolithography (standard and Quickcast), Thermojet, and Laminated Object
Manufacturing processes, and a silicone rubber mold using the RP part as master. We
hope that this investigation, along with the comparative data for major RP processes, will
motivate the industry to explore and adopt this new technology.

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