Reduced consumption of materials and hazardous chemicals for energy efficient production of metal parts through 3D printing of sand molds

Sivarupan, Tharmalingam; Upadhyay, Meet; Ali, Yahia; Mansori, Mohamed El; Dargusch, Matthew S.

doi:10.1016/j.jclepro.2019.03.158

Cited by 39 publications

(13 citation statements)

References 37 publications

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“…Additive manufacturing techniques are currently used to optimise production processes that are based on conventional methods [ 44 ], i.e., casting, etc. The method proposed by the authors could be used to produce prototypical parts that would be ready for testing.…”

Section: Discussionmentioning

confidence: 99%

Additively Manufactured Parts Made of a Polymer Material Used for the Experimental Verification of a Component of a High-Speed Machine with an Optimised Geometry—Preliminary Research

2020

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This paper describes a novel method for the experimental validation of numerically optimised turbomachinery components. In the field of additive manufacturing, numerical models still need to be improved, especially with the experimental data. The paper presents the operational characteristics of a compressor wheel, measured during experimental research. The validation process included conducting a computational flow analysis and experimental tests of two compressor wheels: The aluminium wheel and the 3D printed wheel (made of a polymer material). The chosen manufacturing technology and the results obtained made it possible to determine the speed range in which the operation of the tested machine is stable. In addition, dynamic destructive tests were performed on the polymer disc and their results were compared with the results of the strength analysis. The tests were carried out at high rotational speeds (up to 120,000 rpm). The results of the research described above have proven the utility of this technology in the research and development of high-speed turbomachines operating at speeds up to 90,000 rpm. The research results obtained show that the technology used is suitable for multi-variant optimization of the tested machine part. This work has also contributed to the further development of numerical models.

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Section: Discussionmentioning

confidence: 99%

Additively Manufactured Parts Made of a Polymer Material Used for the Experimental Verification of a Component of a High-Speed Machine with an Optimised Geometry—Preliminary Research

2020

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“…The maximum machine power for the printer is 10300 W with a build (maximum) speed of 3•10 -6 m 3 /s. The specific energy consumption (SECm,c) for manufacturing the sand mould and a core with density 1738 kg/m 3 , is 1.08 MJ/kg [9]. Thus, the total energy consumption (E3D) in 3D printing of sand mould and core can be evaluated from equation 3.…”

Section: Rapid Sand Mouldsmentioning

confidence: 99%

“…As the pattern must be removed to create a cavity, this sometimes limit the geometry to be produced from conventional sand casting [7]. Several researchers have highlighted the importance and advantages of rapid sand casting over traditional sand casting [8][9][10]. However, a robust decision framework has never been implemented in the past to identify the scenarios in which one mould manufacturing method is advantageous over the other, according to the authors' best knowledge.…”

Section: Introductionmentioning

confidence: 99%

Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping

Pagone

Saxena

Papanikolaou

et al. 2020

Sustainable Design and Manufacturing 2020

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Capabilities of Additive Manufacturing (AM) for rapid tooling are well known in recent times. Rapid sand moulds are advantageous over traditional sand moulds in terms of cost, manufacturing time, flexibility, etc. This paper identifies metrics related to mould manufacturing and categorises them into four categories (cost, time, quality and environmental sustainability). A methodology based on the deterministic Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) multi-criteria decision making algorithm is used to map at high-resolution the influence of such categories on to the decision-making space when comparing AM with conventional sand mould making. Results show that AM is almost always clearly advantageous overall (excluding some very limited corner cases) for the examined case.

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“…Así mismo este trabajo se enfoca en el diseño del elemento mediante ingeniería inversa mediante escaneo 3D y fotogrametría del elemento ya indicado www.concienciadigital.org La fundición como proceso de manufactura es necesaria altos consumos de energía por lo cual para que la fundición de estos elementos sea viable económicamente es necesario tener en cuenta la eficiencia energética del proceso (Haraldsson & Johansson, 2018). Tomando en consideración debemos enfocarnos a que este proceso sea amigable con el medio ambiente, es por ellos que la manufactura aditiva nos ayuda a optimizar procesos y ahorrar energía en el proceso de la fundición (Sivarupan et al, 2019).…”

Section: Introductionunclassified

Optimización del proceso de fundición mediante el proceso de ingeniería inversa y aditiva de un cabezote de un motor de bajo cilindraje

2022

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Introducción: En la industria manufactura de piezas y partes en la industria automotriz se ha visto escasamente desarrollada en nuestro país, es por ello por lo que se ha creado políticas gubernamentales como el acuerdo ministerial N 14 264, el cual busca ampliar la gama de productos de fabricación nacional para la industria automotriz. Objetivos: El objetivo se enfoca en la obtención del modelo y los parámetros del proceso de manufactura para obtener un modelo mediante la ingeniería inversa; para conseguir un prototipo de alta calidad y económicamente viable. Metodología: El proceso de manufactura elegido es la fundición en arena el cual es un proceso que nos permite obtener figuras complejas con alta calidad y coste asequible, para ello es necesario realizar el elemento, el procedimiento aplicado es un proceso de escaneo, que el resultado es una nube de punto, para luego transformar a una malla y obtener un elemento sólido obteniendo las características iniciales del proceso. Resultados: Con las características del proceso de moldeo, mediante iteraciones teniendo un error de 0.39 % para un caudal de 0.17285433 ; Y el canal del bebedero tiene una forma tronco cónica teniendo diámetro superior de bebedero de 16,73 mm, y un diámetro inferior del bebedero de 10.21 mm. Conclusiones: Utilizamos manufactura aditiva para el proceso de fundición fue una vez obtenido los valores antes descritos para que la fundición sea óptima, obteniendo un cálculo económico para que nuestro proceso sea competitivo en relación calidad vs costo.

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Reduced consumption of materials and hazardous chemicals for energy efficient production of metal parts through 3D printing of sand molds

Cited by 39 publications

References 37 publications

Additively Manufactured Parts Made of a Polymer Material Used for the Experimental Verification of a Component of a High-Speed Machine with an Optimised Geometry—Preliminary Research

Additively Manufactured Parts Made of a Polymer Material Used for the Experimental Verification of a Component of a High-Speed Machine with an Optimised Geometry—Preliminary Research

Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping

Optimización del proceso de fundición mediante el proceso de ingeniería inversa y aditiva de un cabezote de un motor de bajo cilindraje

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