Process capability study of three dimensional printing as casting solution for non ferrous alloys

Purpose The purpose of this paper is to investigate the process capability of three-dimensional printing (3DP)-based casting solutions for non-ferrous alloy (NFA) components. Design/methodology/approach After selection and design of benchmark, prototypes for six different NFA materials were prepared by using 3DP (ZCast process)-based shell moulds. Coordinate measuring machine has been used for calculating the dimensional tolerances of the NFA components. Consistency with the tolerance grades of the castings has been checked as per IT grades. Findings The results of process capability investigation highlight that the 3DP process as a casting solution for NFA component lies in ±5sigma (s) limit, as regards to dimensional accuracy is concerned. Further, this process ensures rapid production of pre-series industrial prototypes for NFA. Final components prepared are also acceptable as per ISO standard UNI EN 20,286-I (1995). Originality/value This research work presents capability of the 3DP process supported with experimental data on basis of various process parameters for the tolerance grade of NFA castings. These statistics can help to enhance the application of 3DP-based NFA casting process in commercial foundry industry.

[1]  R. Kumar,et al.  Experimental and Analytical Analysis of Light Alloy Shell Castings Using Three Dimensional Printing , 2014 .

[2]  Rajesh Kumar,et al.  Execution of rapid prototyping technology – an Indian manufacturing industry’s perspective , 2013 .

[3]  Hamid Shahriari,et al.  A process capability index for simple linear profile , 2013 .

[4]  Alain Bernard,et al.  Integration of CAD and rapid manufacturing for sand casting optimisation , 2012, ArXiv.

[5]  Rupinder Singh,et al.  Process capability study of polyjet printing for plastic components , 2011 .

[6]  Rupinder Singh,et al.  Experimental investigations for reducing wall thickness in solder (20-80) lead alloy rapid casting solution of three dimensional printing , 2010 .

[7]  R. Singh,et al.  Comparison of Statistically Controlled Machining Solutions of Titanium Alloys using USM , 2010 .

[8]  Rupinder Singh,et al.  Investigations for a statistically controlled rapid casting solution of lead alloys using three-dimensional printing , 2009 .

[9]  Rupinder Singh,et al.  Comparison of rapid casting solutions for lead and brass alloys using three-dimensional printing , 2009 .

[10]  Rupinder Singh,et al.  Experimental investigations for reducing wall thickness in zinc shell casting using three-dimensional printing , 2008 .

[11]  Guru Nānak,et al.  Investigations for deducing wall thickness of aluminium shell casting using three dimensional printing , 2008 .

[12]  D Dimitrov,et al.  Development, evaluation, and selection of rapid tooling process chains for sand casting of functional prototypes , 2007 .

[13]  Andrea Gatto,et al.  3D Printing technique applied to Rapid Casting , 2007 .

[14]  Shey-Huei Sheu,et al.  The evaluation of process capability for a machining center , 2007 .

[15]  K. Leong,et al.  Rapid Prototyping: Principles and Applications (with Companion CD-ROM) , 2003 .

[16]  Wen Lea Pearn,et al.  Capability measures for processes with multiple characteristics , 2003 .

[17]  Djordje Brujic,et al.  CAD-Based Measurement Path Planning for Free-Form Shapes Using Contact Probes , 2000 .

[18]  James G. Conley,et al.  Rapid tooling for sand casting using laminated object manufacturing process , 1999 .

[19]  Mats Deleryd,et al.  On the gap between theory and practice of process capability studies , 1998 .

[20]  Richard E. DeVor,et al.  Statistical Quality Design and Control: Contemporary Concepts and Methods , 1992 .

[21]  Victor E. Kane,et al.  Process Capability Indices , 1986 .

[22]  Douglas C. Montgomery,et al.  Introduction to Statistical Quality Control , 1986 .

[23]  Joseph Moses Juran,et al.  Quality-control handbook , 1951 .