Document Type: Research Paper

Authors

1 Assistant Professor, Faculty of Mechanical Engineering, Malek-Ashtar University of Technology, Shahinshahr, Iran.

2 Mechanical Engineering Department, Sharif University of Technology, Tehran, Iran

Abstract

Thermal expansion and hot deformation are two phenomena that cause dimensional errors in investment casting. This error occur in dimensions between the die pattern and the wax pattern. Therefore, the wax's thermo-physical and thermo-mechanical properties, the metal die features, and the process parameters affect the dimensions of the wax pattern. Some important effective process parameters are the injection temperature, the injection temperature, the die temperature and the holding time. In this paper, the effect of injection parameters on dimensional accuracy of wax models created by a metallic die has been studied. The Taguchi formulation based on design of experiments has been applied in order to obtain the optimum condition to achieve the best dimensional accuracy. The studied specimen with “F” shape has 10 dimensions. The root mean square (RMS) of dimensional differences has been considered for accuracy analysis. The results has shown that if the injection temperature, the injection pressure and the holding time be considered as 80oC, 20 bar, and 2.5 minute, respectively, the best accuracy may be achieved.

Graphical Abstract

Keywords

Main Subjects

[1]      C. Yuan, and S. Jones, "Investigation of fiber modified ceramic moulds for investment casting", J. Europ. Ceram. Soci., Vol. 23, pp. 399-407, (2003).

 

 [2]      J. Jiang, and X.Y. Liu, "Dimensional variations of casting and moulds in the ceramic mould casting process", J. Mater. Process. Tech., Vol. 189, No. 1-3, pp. 247-255, (2007).

  

[3]      J. Fischer, A. Ebinger, T. Hagi, B. Stawarczyk, A. Wenger, and E. Keller, "Mold filling and dimensional accuracy of titanium casting in a spinel-based investment", Dental Materials, Vol. 25, No. 11, pp. 1376-1382, (2009).

  

[4]      R. Singh, S. Singh, and V. Mahajan, "Investigations for dimensional accuracy of investment casting process after cycle time reduction by advancements in shell moulding", Procedia Mater. Sci., Vol. 6, pp. 859-865, (2014).

 

 [5]      R. Singh, J. Singh, and S. Singh, "Investigation for dimensional accuracy of AMC prepared by FDM assisted investment casting using nylon-6 waste based reinforced filament", Measurement, Vol. 79, pp. 253-259, (2016).

 

 [6]      M. Kafara, J. Kemnitzer, H. H. Westermann, and R. Steinhilper, "Influence of binder quantity on dimensional accuracy and resilience in 3D-printing", Procedia Manufacturing, Vol. 21, pp. 638-646, (2018).

  

[7]      J. S. Chohan, R. Singh, K.S. Boparai, R. Penna, and F. Fraternali, "Dimensional accuracy analysis of coupled fused deposition modeling and vapour smoothing operations for biomedical applications", Composites Part B, Vol. 117, pp. 138-149, (2017).

 

 [8]      A.S. Sabau, and S. Viswanathan, "Material properties for predicting wax pattern dimensions in investment casting", Mater. Sci. Eng. A, Vol. 362,pp. 125-134, (2003).

  

[9]      S. A. M. Rezavand, and A. H. Behravesh, "An experimental investigation on dimensional stability of injected wax patterns of gas turbine blades", J. Mater. Proc. Tech., Vol. 182, pp. 580-587, (2007).

  

[10]  P. K. Yarlagadda, and T. S. Hock, "Statistical analysis on accuracy of wax patterns used in investment casting process", J. Mater. Proc. Tech., Vol. 138, pp. 75-81, (2003).

  

[11]  T. L. Chang, C. Maruyama, S. N. White, S. Son, and A. A. Caputom, "Dimensional accuracy analysis of implant framework casting from two casting systems", J. Prosth. Dent., Vol. 96, pp. 67-75, (2006).

  

[12]  W. Bonilla, S. H. Masood, and P. Iovenitti, "An investigation of wax patterns for accuracy improvement in investment cast parts", Int. J. Advanced Manufacturing Technology, Vol. 18, pp. 348-356, (2001).

  

[13]  J. C. Gebelin, M. R. Jolly, A. M. Cendrowicz, S. Blackburn, and J. Cirre, "Simulation of die filling for the wax injection process: Part I. models for material behavior", Metal Mater. Trans. B, Vol. 35, pp. 755-759, (2004).

  

[14]  J. C. Gebelin, M. R. Jolly, A. M. Cendrowicz, S. Blackburn, and J. Cirre, "Simulation of die filling for the wax injection process: Part II. Numerical simulation", Metal Mater. Trans. B, Vol. 35, pp. 760-768, (2004).

  

[15]  D. Singh, R. Singh, and K. S. Boparai, "Development and surface improvement of FDM pattern based investment casting of biomedical implants: A state of art review", J. Manuf. Proc., Vol. 31, pp. 80-95, (2018).

  

[16]  P. Kumar, R. Singh, and I.P. Ahuja, "Investigations on dimensional accuracy of the components prepared by hybrid investment casting", J. Manuf. Process, Vol. 20, No. 3, pp. 525-533, (2015).

  

[17]  J. Singh, and H. Singh, "Dimensional accuracy and surface finish of biomedical implant fabricated as rapid investment casting for small or medium quantity production", J. Manuf. Proc., Vol. 25, pp. 201-211, (2017).

  

[18]  R. Singh, S. Singh, and G. Singh, "Dimensional accuracy comparison of investment castings prepared with wax and ABS patterns for bio-medical application", Procedia Mater. Sci., Vol. 6, pp. 851-858, (2014).

  

[19]  R. Singh, R. Singh, J.S. Dureja, I. Farina, and F. Fabbrocino, "Investigations for dimensional accuracy of Al alloy/Al-MMC developed by combining stir casting and ABS replica based investment casting", Composites Part B, Vol. 115, pp. 203-208, (2017).

  

[20]  R. Singh, and S. Singh, "Modeling of dimensional accuracy in precision investment casting using Buckingham's Pi approach", Materialstoday, Vol. 4, No. 2, Part A, pp. 1598-1605, (2017).

  

[21]  Y. W. Dong, X. L. Li, Q. Zhao, J. Yang, and M. Dao, "Modeling of shrinkage during investment casting of thin-walled hollow turbine blades", J. Mater. Process. Tech., Vol. 244, pp. 190-203, (2017).

  

[22]  J. Barbosa, and H. Puga, "Ultrasonic melt processing in the low pressure investment casting of Al alloys", J. Mater. Process. Tech., Vol. 244, pp. 150-156, (2017).

  

[23]  D.Y. Park, D.S. Shin, H. Cho, and S.J. Park, "Effects of material and processing conditions on powder-binder separation using the Taguchi method", Powder Tech., Vol. 321, pp. 369-379, (2017).

  

[24]  R. Valinejad, and R. Soleymani Nazar, "An experimental design approach for investigating the effects of operating factors on the wax deposition in pipelines", Fuel, Vol. 106, pp. 843-850, (2013).

 

 [25]  J. Sun, Y. Yang, and D. Wang, "Parametric optimization of selective laser melting for forming Ti6Al4V samples by Taguchi approach", Optics Laser Tech., Vol. 49, pp. 118-124, (2013).

 

 [26]  O. Tan, A. S. Zaimoglu, S. Hinislioglu, and S. Altun, "Taguchi approach for optimization of the bleeding on cement-based grouts", Tun Underground Spa. Tech., Vol. 20, pp. 167-173, (2005).

 

 [27]  R. K. Roy, Design of experiments using the Taguchi approach. 3rd edition, Wiley, Mississauga, ISBN: 0-471-36101-1, (2001).

 

 [28]  K. K. Prasad, S. V. Mohan, R. S. Rao, B. R. Pati, and P. N. Sarma, "Laccase production by Pleurotus ostreatus 1804: optimization of submerged culture conditions by Taguchi DOE methodology", Bio Engineering J., Vol. 24, pp. 17-26, (2005).

CAPTCHA Image