Robotyping – new rapid prototyping processes for sand moulds using industrial robots

Schaaf, Walter

doi:10.1108/01445150010378443

Cited by 4 publications

(2 citation statements)

References 6 publications

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“…There has been some research in other technologies that use subtractive methods and hybrid approaches using additive and subtractive means. Schaaf (2000) presented a sand mold RP technique using industrial robots. The technique requires a considerable amount of time to produce a sand mold compared to traditional approaches; therefore it is limited to low‐volume sand casting production.…”

Section: Background and Related Workmentioning

confidence: 99%

A layer thickness algorithm for additive/subtractive rapid pattern manufacturing

Luo

Frank²

2010

Rapid Prototyping Journal

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PurposeThe purpose of this paper is to present an algorithm for an additive/subtractive rapid pattern manufacturing (RPM) process where thick slabs of material are sequentially stacked and then cut to 3D shapes. Unlike traditional rapid prototyping processes where layer thickness is typically uniform, this process is able to vary the layer thickness in order to most effectively generate feature shapes.Design/methodology/approachThis paper discusses the factors affecting layer thickness decisions and then presents an algorithm to determine layer thicknesses for a given part model. The system is designed to import a computer‐aided design file and use the algorithm to automatically generate the set of layers based on the slab height, material and bonding properties and the process parameters used in the system.FindingsThe layer thickness algorithm is implemented and tested using an additive/subtractive manufacturing system developed in the laboratory. The algorithm has proved effective in determining appropriate layer heights for thick slab machining, taking into account a variety of geometries. Several sand casting patterns have been successfully created using the proposed system, which could significantly improve traditional sand casting pattern manufacturing.Originality/valueThe proposed RPM process is a new process presented by the authors, developed for rapid sand castings. The layer thickness algorithm is an original contribution that enables automatic process planning for this new process.

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Section: Background and Related Workmentioning

confidence: 99%

A layer thickness algorithm for additive/subtractive rapid pattern manufacturing

Luo

Frank²

2010

Rapid Prototyping Journal

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“…On the contrary, in applications where flexibility, complex surfaces, rapid prototype machining operations and, especially, stiffness are not an important requirement, industrial robots may be the ideal machine tool. Among such applications, some can be listed: rapid prototyping, burr removal, and even drilling, provide that all materials being machined are low strength and easy to cut ones (Schaaf, 2000). Among those are some aluminum alloys, magnesium alloys, wood, plastics and also some composites with plastic/resin matrices and low strength reinforcements (Cezary et al, 2003;Huang, et al, 2002).…”

Section: Introduction Amentioning

confidence: 99%

An Investigation into the Use of Industrial Robots for Machining Soft and Low Density Materials with HSM Technique

Coelho

Rodella

Martins

et al. 2011

J. Braz. Soc. Mech. Sci. & Eng.

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The needs to comply with an increasingly competitive international market lead industries to some innovative solutions, such as the use of robotic arms as machine tools. Although these solutions present some well known drawbacks, there are some advantages and niches of application where success is possible. The present work investigates the use of such pieces of equipment to machine aluminum alloys AA2024 applying high speed machining (HSM) technique, assessing surface finishing as a function of different orientation angles between end mill and machined surface. It also tests the best condition to machine foam for prototyping applications. Results indicate that the directions close to the normal are the best compromises because of dynamic stability of the robot arm structure and roughness as low as 4 µm Ra are possible to be achieved in aluminum alloys. A complex shape such as a semi sphere can be easily machined in foam for rapid and accurate prototype machining. Surface finishing can be very smooth and well suitable for industrial applications in such materials

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Rapid Prototyping and Manufacturing: A Review of Current Technologies

́n-Castillo

Torres

2009

Volume 4: Design and Manufacturing

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The idea to develop processes capable to produce physical components quickly and without requiring tooling, led to the development of the “free form fabrication” (FFF) or “rapid prototyping” (RP) technologies in the early 1980s. RP systems generally build up a prototype directly from the computer-aided design (CAD) data by using an additive “layer by layer” method. The RP technologies have brought several advantages to the manufacturing industry in such a way that these technologies are evolving toward the production of end-use parts. This paper presents a review of rapid prototyping and manufacturing (RP&M) technologies from their origins. The review includes commercially available RP systems and RP technologies that are still at the development stage or that have been proposed. The operating principles and the features of these technologies are presented. Process parameters such as accuracy, layer thickness, operation speed are given. An extended classification of RP&M technologies is also included in this paper.

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Robotyping – new rapid prototyping processes for sand moulds using industrial robots

Abstract: This article describes new approaches in rapid prototyping large sand moulds using industrial robots. In contrast to state of the art processes, the new approaches work three‐dimensionally taking advantage of the large working area of industrial robots.

Cited by 4 publications

References 6 publications

A layer thickness algorithm for additive/subtractive rapid pattern manufacturing

A layer thickness algorithm for additive/subtractive rapid pattern manufacturing

An Investigation into the Use of Industrial Robots for Machining Soft and Low Density Materials with HSM Technique

Rapid Prototyping and Manufacturing: A Review of Current Technologies

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