Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study
The need to manufacture a copy of a mechanical part typically arises when a single replacement part is necessary and is out of stock or out of production altogether. For parts with intricate details and associated accuracy requirements, investment casting may be preferred to machining, for size and...
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doaj-e0b3c18344464dde883e09924a85e5592020-11-24T21:15:23ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942017-11-01121710.3390/jmmp1020017jmmp1020017Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case StudyGeorge-Christopher Vosniakos0Stefanos Michael1Anastasia Vasileiou2School of Mechanical Engineering, National Technical University of Athens, Heroon Polytehneiou 9, 15780 Athens, GreeceSchool of Mechanical Engineering, National Technical University of Athens, Heroon Polytehneiou 9, 15780 Athens, GreeceSchool of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester M13 9PL, UKThe need to manufacture a copy of a mechanical part typically arises when a single replacement part is necessary and is out of stock or out of production altogether. For parts with intricate details and associated accuracy requirements, investment casting may be preferred to machining, for size and detail reasons, or 3D printing, for material reasons. This work applies the digital manufacturing paradigm to one-off vacuum-aided rapid investment casting focusing on the process chain rather than on engineering issues. 3D laser scanning, digital model construction by surface fitting, casting model making by exploiting additive manufacturing, material investigation using scanning electron microscopy, casting simulation exploring process parameter scenarios, as well as the corresponding implementation on a vacuum casting machine are the pertinent interlinked steps and techniques. The added value of this work is that for each process link the important steps and the potential pitfalls are analyzed in detail using as an example a cylinder liner from a model car engine. Quality of the result was quite acceptable, the main benefit of the streamlined approach being that “right-first-time” parts can be achieved.https://www.mdpi.com/2504-4494/1/2/17investment castingone-off manufacturing3D scanningsurface reconstructioncasting simulationadditive manufacturingdigital manufacturingprocess chain |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
George-Christopher Vosniakos Stefanos Michael Anastasia Vasileiou |
spellingShingle |
George-Christopher Vosniakos Stefanos Michael Anastasia Vasileiou Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study Journal of Manufacturing and Materials Processing investment casting one-off manufacturing 3D scanning surface reconstruction casting simulation additive manufacturing digital manufacturing process chain |
author_facet |
George-Christopher Vosniakos Stefanos Michael Anastasia Vasileiou |
author_sort |
George-Christopher Vosniakos |
title |
Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study |
title_short |
Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study |
title_full |
Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study |
title_fullStr |
Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study |
title_full_unstemmed |
Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study |
title_sort |
digital manufacturing process chain for one-off replacement parts: a precision casting case study |
publisher |
MDPI AG |
series |
Journal of Manufacturing and Materials Processing |
issn |
2504-4494 |
publishDate |
2017-11-01 |
description |
The need to manufacture a copy of a mechanical part typically arises when a single replacement part is necessary and is out of stock or out of production altogether. For parts with intricate details and associated accuracy requirements, investment casting may be preferred to machining, for size and detail reasons, or 3D printing, for material reasons. This work applies the digital manufacturing paradigm to one-off vacuum-aided rapid investment casting focusing on the process chain rather than on engineering issues. 3D laser scanning, digital model construction by surface fitting, casting model making by exploiting additive manufacturing, material investigation using scanning electron microscopy, casting simulation exploring process parameter scenarios, as well as the corresponding implementation on a vacuum casting machine are the pertinent interlinked steps and techniques. The added value of this work is that for each process link the important steps and the potential pitfalls are analyzed in detail using as an example a cylinder liner from a model car engine. Quality of the result was quite acceptable, the main benefit of the streamlined approach being that “right-first-time” parts can be achieved. |
topic |
investment casting one-off manufacturing 3D scanning surface reconstruction casting simulation additive manufacturing digital manufacturing process chain |
url |
https://www.mdpi.com/2504-4494/1/2/17 |
work_keys_str_mv |
AT georgechristophervosniakos digitalmanufacturingprocesschainforoneoffreplacementpartsaprecisioncastingcasestudy AT stefanosmichael digitalmanufacturingprocesschainforoneoffreplacementpartsaprecisioncastingcasestudy AT anastasiavasileiou digitalmanufacturingprocesschainforoneoffreplacementpartsaprecisioncastingcasestudy |
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