Abstract
3D printing technology has been used for sand molding and core printing, but they simply substitute the traditional molding and core making method without changing the shape or size of the sand mold (core) and their dense structure. In this study, a new type of hollow mold based on 3D printing is presented. The new type of mold is a rib reinforced thickness-varying shell mold. This mold design can realize the controlled cooling of castings, i.e., different cooling rates at different areas, and improve the temperature uniformity of a casting after its solidification. Therefore, the performance of castings can be improved and their residual stress and deformation can be reduced. This kind of new mold was applied to a stress frame of A356 aluminum alloy. The 3D printed rib reinforced thickness-varying shell mold was compared with the traditional dense mold, and the castings obtained by these two kinds of molds were also compared. The experimental results showed that the rib reinforced shell mold increased the cooling rate of the casting by 30%, tensile strength by 17%, yield strength by 11%, elongation by 67%, and decreased its deformation by 43%, while sand consumption was greatly reduced by 90%.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Shan Zhongde, Chen Shaokai, Chen Wengang, et al. Research on Pattern-less NC Forming Fast Production of Automobile Castings. Modern Cast Iron, 2010, (spec. issue): 81–85. (In Chinese)
Liu Jiang. The shell molding process study for mass production of single-cylinder diesel engine crankshaft. Applied Mechanics and Materials, 2011,44-47: 284–288.
Long Wei, Fan Zitian. The situation and progress of the recycling of old sand. China Foundry Machinery & Technology, 2012 (2): 1–5. (In Chinese)
Xing Wanting, Liu Yue, Xin Qibin, et al. Research progress and application of old sand regeneration. Foundry, 2015, 64(8): 735–739. (In Chinese)
Thomas B, John U. 3D, SF and the future. Futures, 2013, 50: 25–34.
Kirleis M A, Simonson D, Charipar N A, et al. Laser embedding electronics on 3D printed objects. In: Proc. SPIE -The International Society for Optical Engineering, California, 2014, 8970: 1–7.
Kang Jinwu, Ma Qiangxian. The role and impact of 3D printing technologies in casting. China Foundry, 2017, 14(3): 157–168.
Dutta B, Froes F H. Titanium Powder Metallurgy. Science, Technology and Applications. Elsevier, 2015: 447–468.
Sun D, Xu X C, Wang D H, Liu K F, et al. Rapid investment casting process for impeller based on 3D printing technology. Special Casting & Nonferrous Alloys, 2016, 36(11): 1172–1174. (In Chinese)
Li S P, Zheng D Q, Wang H F. Application of 3D printed investment casting technology in the manufacturing of engines. Agro Food Industry Hi Tech, 2017(28): 1419–1421.
Chunze Y, Liang H, Ahmed H, et al. Evaluation of light-weight AlSi10Mg periodic cellular lattice structures fabricated via direct metal laser sintering. Journal of Materials Processing Technology, 2014, 214: 856–864.
Druschitz A, Williams C, Snelling D, et al. Additive manufacturing supports the production of complex castings. 143rd Annual Meeting and Exhibition, USA: Shape Casting, 2014: 51–57.
Snelling D, Li Q, Meisel N, et al. Lightweight Metal Cellular Structures Fabricated via 3D Printing of Sand Cast Moulds. Advanced Engineering Materials, 2015, 17(7): 923–932.
Snelling D, Blount H, Charles F, et al. The effects of 3D printed molds on metal castings. In: Proc. 24th International SFF Symposium -An Additive Manufacturing Conference, SFF, 2013: 827–845.
Casalino G, Filippis L.A.C. D, Ludovico A. A technical note on the mechanical and physical characterization of selective laser sintered sand for rapid casting. Journal of Materials Processing Technology, 2005, 166: 1–8.
Wood K, Ravi S. Design Considerations for Three Dimensional Printed Cores and Molds. In: Proc. 119th Metal casting Congress, Columbus, 2015, 24–29.
Crommert S V D, Seitz, S, Esser, K K., et al. Sand, die and investment cast parts via the SLS® selective laser sintering process. In: Proc. SPIE -The International Society for Optical Engineering, Munich, 1997, 3102: 95–105.
LI Y, Ola H, Denis C, et al. Additive Manufacturing of Metal Cellular Structures: Design and Fabrication. JOM, 2015, 67(3): 608–615.
Adithya C, Ju J. Continuum model for effective properties of orthotropic octet-truss lattice materials. In: Proc. ASME International Mechanical Engineering Congress and Exposition, Montreal, 2014: 1–5.
Chen Y. 3D Texture Mapping: A Microstructure Design Method for Rapid Manufacturing. Computer-Aided Design & Applications, 2007, 4(6): 761–771.
Chen Y, Wang S L. Computer-aided Product Design with Performance-Tailored Mesostructures. Computer-Aided Design & Applications, 2008, 5(1-4): 1–11.
Guido A.O.A, Detmar Z. Design for Additive Manufacturing-Element transitions and aggregated structures. CIRP Journal of Manufacturing Science and Technology, 2014, 7: 20–28.
Kang Jinwu, Shangguan Haolong, Deng Chenyang. New mold of non-dense structure. China Patent, 109313716, 2015. (In Chinese)
Kang Jinwu, Shangguan Haolong, Hu Yongyi. New mold of double shell structure. China Patent, 101255666, 2016. (In Chinese)
Shangguan Haolong, Kang Jinwu, Deng Chenyang, et al. 3D-printed shell-truss sand mold for aluminum castings, Journal of Materials Processing Technology, 2017, 250: 247–253.
Author information
Authors and Affiliations
Corresponding author
Additional information
Male, born in 1970, Associate Professor, Ph.D. His research interests maily focus on the modelling and simulation of casting process and solidification. His academic research has led to the publication of more than 160 papers in journals such as Metallurgical and Materials Transactions, Materials Science and Engineering, and so on.
Rights and permissions
About this article
Cite this article
Shangguan, Hl., Kang, Jw., Yi, Jh. et al. Controlled cooling of an aluminum alloy casting based on 3D printed rib reinforced shell mold. China Foundry 15, 210–215 (2018). https://doi.org/10.1007/s41230-018-7252-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s41230-018-7252-x