Feasibility and sustainability evaluation of 3D printed fused deposition modeling patterns for investment casting
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Insinööritieteiden korkeakoulu |
Master's thesis
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Authors
Date
2023-09-25
Department
Major/Subject
Mechanical Engineering
Mcode
Degree programme
Master's Programme in Mechanical Engineering (MEC)
Language
en
Pages
102
Series
Abstract
Casting process is a very old manufacturing process which has remained the same for many decades. However, the advent of 3d printers is bringing a manufacturing revolution and the casting processes such as Investment and sand casting are not immune to this new change.3D printing is now being integrated with existing casting process in order to reduce the tooling time and cost. This hybrid approach is being used to produce patterns and Moulds to be used in low to medium volume production. This thesis deals with investigating the suitability of patterns printed with the Fused deposition modelling process for Investment casting. The work starts with selecting the suitable materials according to different properties and then printing the patterns to check their printability. Then, suitable material process parameters were shortlisted, and larger patterns were printed. At the same time, energy calculation was carried out with the help of an energy meter to determine the total energy consumption in printing out the patterns. As the patterns are made available, 3d scanning was done on the patterns to analyse the contraction and expansions produced in them. In parallel, Ash content tests for the different materials were performed. After printing of all the patterns, investment casting shell was made, and they were checked for any shell defects. Afterwards, the shells were invested cast using aluminium and final castings were further analysed with 3d scanners and compared with the original cad file model for dimensional deviations. Side by side, Carbon emissions of the material were determined for the purpose of studying sustainability of the process. Also, Cost analysis of the materials was also executed. In the end, results were made available, and conclusions based on suitability of patterns, sustainability aspects, energy calculations and cost analysis were made.Description
Supervisor
Orkas, JuhaniThesis advisor
Jalava, KalleKeywords
hybrid investment casting, FDM, shell crack, wall thickness, carbon emissions, ash content