Evaluation of sand casting patterns and tooling produced by fused deposition modeling
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Insinööritieteiden korkeakoulu |
Master's thesis
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Authors
Date
2023-08-21
Department
Major/Subject
Mcode
Degree programme
Master's Programme in Mechanical Engineering (MEC)
Language
en
Pages
82+6
Series
Abstract
This thesis explores the use of fused deposition modeling (FDM) as a tool for producing patterns for sand casting. FDM, an additive manufacturing technique, offers advantages such as design flexibility, material versatility, and cost and time savings compared to traditional machining methods. The study includes the metrological analysis of patterns, sand molds, and castings using 3D scanning. Eight different FDM materials are analyzed which include PLA, PLA-PHA, Tough-PHA, AllPHA, ABS, PLA, PETG, and ASA, with patterns printed in two different sizes. The research aims to determine the optimal materials and process parameters for pattern printing in sand casting applications. The findings indicate that FDM is capable of producing complex-shaped patterns with good dimensional accuracy for sand casting. The 3D printed patterns and molds exhibited acceptable dimensional deviations within the range of ±0.25 mm. However, the castings showed higher deviations, reaching up to ±2 mm. Quality of molds and castings can be improved by optimizing the relevant process, respectively.Description
Supervisor
Orkas, JuhaniThesis advisor
Jalava, KalleKeywords
sand casting, additive manufacturing, fused deposition modeling, 3D scanning, rapid tooling