Lesson 255 of IEKC Industrial Engineering ONLINE Course Notes.
Engineering in Industrial Engineering - Machine work study or machine effort improvement, value engineering and design for manufacturing and assembly are major engineering based IE methods. All are available as existing methods.
Product Design for Manufacture and Assembly, Third Edition
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
CRC Press, 08-Dec-2010 - Technology & Engineering - 712 pages
https://books.google.co.in/books/about/Product_Design_for_Manufacture_and_Assem.html?id=W2FDCcVPBcAC
Note: It is important to read the books by Boothroyd to understand the full method of DFMA. The DFMA method is to be combined with Value Analysis and Engineering to do product industrial engineering. In the note only attempt is made to make readers aware of issues raised and solutions proposed by DFMA method.
Chapter 13. Design for Investment Casting 549
DESIGN GUIDELINES
The investment casting process was previously known as the "lost wax" process. Its advantage over other casting processes is its ability to produce very complex castings with fine details. Investment casting offers greater freedom in design than any other metal forming operation. Accurate and intricate castings can be made from alloys that melt at high temperature. Parts can be cast to such close tolerance that little or no machining is required.
The wax or plastic patterns will be produced by injection molding. Therefore, guidelines similar to those for injection molding apply to the pieces of the pattern that will be used to make up the final pattern shape. Thus the pattern piece must be easily removable from its mold and the main wall should have a uniform thickness, which will minimize distortion by facilitating even cooling throughout the pattern piece. In addition, the principles of good sand casting design also apply to investment casting. For example, nonfunctional mass should be minimized to assist in providing sufficient gating to "feed" the part. Also, uniform wall sections with generous radii and fillets will assist in metal flow and reduce stress concentrations.
Separate cores can add significantly to the cost, as well as bosses and undercuts. The minimum section ranges from 0.25 to 1 mm depending upon the metal to be cast. The maximum section is approximately 75 mm.
Castings range from 0.5g to 100kg in weight, but the investment casting process is best for parts that weigh less than 5 kg. A flat parting plane for each pattern piece will help to minimize the cost.
http://americancastingco.com/blog/investment-casting-design-considerations-and-tips/
Rapid Investment Casting: Design and Manufacturing Technologies
Christopher T. Richard, Tsz-Ho Kwok
ASME 2019 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference
August 18–21, 2019
Anaheim, California, USA
RIC (Rapid investment casting) takes advantage of the additive nature of 3D printing for pattern making which allows for more complex castings than traditional investment casting. RIC is a manufacturing process that combines the casting knowledge accumulated over five thousand years with relatively novel AM knowledge. The result is a process that can compete with newer metal AM methods with the added benefits of excellent surface finish, fatigue strength and the ability to create parts from almost any metal or metal alloy. This article will focus on research advancements in investment casting, AM and all the topics that are closely related to optimizing these two processes.
AN ANALYTICAL COST MODEL FOR INVESTMENT CASTING
DS 102: Proceedings of the DESIGN 2020 16th International Design Conference, Year: 2020
Author: Mandolini, M., Campi, F., Favi, C., Cicconi, P. and Germani, M.
https://www.designsociety.org/publication/42575/AN+ANALYTICAL+COST+MODEL+FOR+INVESTMENT+CASTING
Gating System Design Optimization for Investment Casting Process
February 2019, Journal of Materials Engineering and Performance 28(54)
Marek Brůna et al.
REFERENCES 1. Horton, R.A., Investment Casting, ASM Handbook, Vol. 15, Casting. ASM International, Metals Park, OH, 1998.
2. McCloskey, 1C., Productivity in Investment Casting, American Jewelry Manufacturing, Vol. 38, No. 6, June 1990, p. 32.
3. Niebel, B.W., Draper, A.B., and Wysk, R.A., Modern Manufacturing Process Engineering, McGraw-Hill, New York, 1989.
4. Royer, A., and Vasseur, S., Centrifugal Casting, ASM Handbook, Vol. 15, Casting, ASM International, Metals Park, OH, 1988.
Ud 13.12.2021
Pub 6.12.2021
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