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A Study of Mixed Manufacturing Methods in Sand Casting Using 3D Sand Printing and FDM Pattern-making Based on Cost and Time

Gullapalli, Ram A
http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485335857475363

Abstract Details

2016, Master of Science in Engineering, Youngstown State University, Department of Mechanical, Industrial and Manufacturing Engineering.
Sand casting has long been known to be an effective manufacturing method for metal casting and especially for parts of large dimensions and low production volume. But, for increasing complexity, the conventional sand casting process does have its limitations; one of them mainly being the high cost of tooling to create molds and cores. With the advent of additive manufacturing (AM), these limitations can be overcome by the use of a 3D sand printer which offers the unique advantage of geometric freedom. Previous research shows the cost benefits of 3D sand printing molds and cores when compared to traditional mold and core making methods. The line of research presented in this thesis introduces the idea of additive manufacturing at different stages of the sand casting process and investigates the decision-making process as well as the cost-based effects. This will enable foundries and manufacturers to integrate the use of AM machines more smoothly into their production process without the need for completely re-engineering the existing production system. A critical part of this thesis is the tooling cost estimation using a casting cost model that is significantly accurate to industry standard quotes. Based on these considerations, this thesis outlines three approaches for achieving this goal apart from traditional mold and core making methods. The first approach integrates 3D Printing at the pattern making level where the patterns and core-boxes are “printed” on an FDM printer. This eliminates the tooling costs associated with a traditional sand casting method. The second approach integrates 3D Printing at the core-making level by “mixing” traditional mold-making process and 3D sand printing process for core-making. The third approach, the 3D sand printer is used to create both the molds and the cores, thereby eliminating the need for traditional methods. An initial hypothesis is created which states that, for a given production volume, with increased complexity of the casting, additively manufacturing only the cores and conventionally manufacturing the molds is cost-feasible when compared to traditional manufacturing or 3D sand printing. It is finally concluded that the initial hypothesis is valid when part geometries are highly complex and production volumes range between medium to high. It is also concluded that a decision making tool based on the methodology provided can help determine a specific mixed manufacturing method for the manufacturer.
Brett Conner, PhD (Advisor)
Darrell Wallace, PhD (Committee Member)
Eric MacDonald, PhD (Committee Member)
89 p.
Economics; Engineering; Mechanical Engineering
3D Printing; Additive Manufacturing; Manufacturing; Sand Casting; Casting; Molds; Cores; Patterns; Pattern-making; 3D printed parts;

Recommended Citations

Citations

  • Gullapalli, R. A. (2016). A Study of Mixed Manufacturing Methods in Sand Casting Using 3D Sand Printing and FDM Pattern-making Based on Cost and Time [Master's thesis, Youngstown State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485335857475363

    APA Style (7th edition)

  • Gullapalli, Ram. A Study of Mixed Manufacturing Methods in Sand Casting Using 3D Sand Printing and FDM Pattern-making Based on Cost and Time. 2016. Youngstown State University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485335857475363.

    MLA Style (8th edition)

  • Gullapalli, Ram. "A Study of Mixed Manufacturing Methods in Sand Casting Using 3D Sand Printing and FDM Pattern-making Based on Cost and Time." Master's thesis, Youngstown State University, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=ysu1485335857475363

    Chicago Manual of Style (17th edition)

ysu1485335857475363
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This open access ETD is published by Youngstown State University and OhioLINK.