Optimization of vacuum casting process parameters to enhance tensile strength of components using design of experiments approach

Kuo, Chil-Chyuan; Liu, Hsueh-An; Chang, Chao-Ming

doi:10.1007/s00170-019-04905-6

Cited by 8 publications

(4 citation statements)

References 43 publications

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“…The average tensile force of the commercially available PLA filaments is about respectively 139.5 N. However, the average tensile force of the PLA filaments produced by this work is about respectively 154.6 N. These results indicate that the tensile force of the PLA filament produced by this work is about 1.1 times that of the commercially available PLA filament. This means that the developed PLA filaments can be used for direct soft tooling [ 42 , 43 ] application since the mold fabricated possesses high tensile strength [ 44 , 45 ], which can be used for small-volumn production. The commercially available PLA material is NTD 0.25/g.…”

Section: Resultsmentioning

confidence: 99%

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

2021

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The amount of wasted polylactic acid (PLA) is increasing because 3D printing services are an increasingly popular offering in many fields. The PLA is widely employed in the fused deposition modeling (FDM) since it is an environmentally friendly polymer. However, failed prototypes or physical models can generate substantial waste. In this study, the feasibility of recycling PLA waste plastic and re-extruded it into new PLA filaments was investigated. An automatic PLA filament extruder was first developed for fabricating new PLA filaments. This paper also discusses the process, challenges, and benefits of recycling PLA waste plastic in an effort to fabricate new PLA filaments more sustainable. It was found that it was possible to fabricate PLA filament using recycled PLA waste plastic. The production cost is only 60% of the commercially available PLA filament. The tensile strength of the developed PLA filament is approximately 1.1 times that of the commercially available PLA filament. The design of experiments approach was employed to investigate the optimal process parameters for fabricating PLA filaments. The most important control factor affecting the diameter of PLA filament is the barrel temperature, followed by recycled material addition ratio, extrusion speed, and cooling distance. The optimal process parameters for fabricating PLA filament with a diameter of 1.7 mm include the barrel temperature of 184 °C, extrusion speed of 490 mm/min, cooling distance of 57.5 mm, and recycled material addition ratio of 40%.

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Section: Resultsmentioning

confidence: 99%

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

2021

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“…3D printed sprue distribution systems can be used for molds with multiple cavities (Figure 1c). Flow simulations can be used to improve the positioning of risers to avoid air pockets [18,19].…”

Section: Silicone Mold Productionmentioning

confidence: 99%

Industrial‐scale vacuum casting with silicone molds: A review

Wortmann

Frese

2022

Applied Research

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Vacuum casting (VC) of reactive polymer resins in silicone molds is one of the oldest rapid tooling methods. It is widely used in the industry for prototype and small‐series production of thermoset plastic parts. Despite its widespread use, its scientific exploration is still scarce compared to other prototyping methods, such as three‐dimensional (3D) printing. Compared to conventional 3D printing methods, a wide range of excellent material properties can be achieved, making it well suited for the production of functional prototypes and even final products. The properties of the thermosets are comparable to those of injection molding in terms of viable shapes, mold fidelity, and material properties. However, due to the high cycle time and limited service life of the molds, VC is rarely utilized for mid‐ or large‐series production. Here, we provide a comprehensive overview of the state of the art and recent advances in the field. The review also provides a detailed technical introduction to the mold production, the process flow, and the materials used. A particular focus is on the key challenges facing industrial‐scale VC today—how to reduce cycle time, and how to increase mold service life?

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“…Furthermore, it is reported that vacuum casting reduces the concentration of oxygen and hydrogen in the liquid metal by a factor of two and leads to better finishing and mechanical properties. Kuo et al [9] used experimental design methods combined with the Vacuum Differential Pressure Casting (VDPC) technique to improve the tensile strength of castings with a focus on the production of the moulds. The mould cavity temperature is identified as the primary parameter (with an optimal cavity temperature of 35 °C) followed by the mixing time (with 40 s as optimal), differential pressure time (best at 8 s) and mixing chamber inlet valve angle (optimal at 60°).…”

Section: Introductionmentioning

confidence: 99%

Defect Minimisation in Vacuum-Assisted Plaster Mould Investment Casting Through Simulation of High-Value Aluminium Alloy Components

Pagone

Jones

Forde³

et al. 2023

The Minerals, Metals &Amp; Materials Series

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Vacuum assisted plaster mould investment casting is one of the best available processes to manufacture ultra-high complexity castings for the aerospace and defence sectors. In light of the emerging cross sectoral manufacturing industry digitalisation, process simulation appears as a very important tool to improve casting yield, reduce metallurgical scrap and reduce lead time to new product introduction. Considering the unique aspects and the level of customisation of the process system, this work will present a Computational Fluid Dynamics based simulation tool with bespoke settings (that include thermo-physical properties). Optimal fill and solidification parameters are identified for a representative geometry able to describe a variety of very complex, high value aluminium alloy components through an iterative process.

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Optimization of vacuum casting process parameters to enhance tensile strength of components using design of experiments approach

Cited by 8 publications

References 43 publications

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

Optimization of Process Parameters for Fabricating Polylactic Acid Filaments Using Design of Experiments Approach

Industrial‐scale vacuum casting with silicone molds: A review

Defect Minimisation in Vacuum-Assisted Plaster Mould Investment Casting Through Simulation of High-Value Aluminium Alloy Components

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