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J. Manuf. Mater. Process. 2017, 1(2), 17; doi:10.3390/jmmp1020017

Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study

1
School of Mechanical Engineering, National Technical University of Athens, Heroon Polytehneiou 9, 15780 Athens, Greece
2
School of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester M13 9PL, UK
*
Author to whom correspondence should be addressed.
Received: 31 August 2017 / Revised: 4 November 2017 / Accepted: 9 November 2017 / Published: 13 November 2017
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Abstract

The need to manufacture a copy of a mechanical part typically arises when a single replacement part is necessary and is out of stock or out of production altogether. For parts with intricate details and associated accuracy requirements, investment casting may be preferred to machining, for size and detail reasons, or 3D printing, for material reasons. This work applies the digital manufacturing paradigm to one-off vacuum-aided rapid investment casting focusing on the process chain rather than on engineering issues. 3D laser scanning, digital model construction by surface fitting, casting model making by exploiting additive manufacturing, material investigation using scanning electron microscopy, casting simulation exploring process parameter scenarios, as well as the corresponding implementation on a vacuum casting machine are the pertinent interlinked steps and techniques. The added value of this work is that for each process link the important steps and the potential pitfalls are analyzed in detail using as an example a cylinder liner from a model car engine. Quality of the result was quite acceptable, the main benefit of the streamlined approach being that “right-first-time” parts can be achieved. View Full-Text
Keywords: investment casting; one-off manufacturing; 3D scanning; surface reconstruction; casting simulation; additive manufacturing; digital manufacturing; process chain investment casting; one-off manufacturing; 3D scanning; surface reconstruction; casting simulation; additive manufacturing; digital manufacturing; process chain
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Vosniakos, G.-C.; Michael, S.; Vasileiou, A. Digital Manufacturing Process Chain for One-Off Replacement Parts: A Precision Casting Case Study. J. Manuf. Mater. Process. 2017, 1, 17.

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