Plaster casting process for prototyping of die casting based on rapid tooling |
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Authors: | KD Kim DY Yang and JH Jeong |
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Affiliation: | (1) Department of Mechanical Engineering, Korea Advanced Institute of Science and Technology, 373-1, Science Town, Daejeon, 305-701, South Korea;(2) Department of Intelligent of Precision Machine, Korea Institute of Machinery & Materials, P.O.BOX 101, Yusong, Daejeon, South Korea |
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Abstract: | Rapid prototyping (RP) combined with a gravity casting process can provide a suitable substitute with steel tool die casting
for prototyping metal casting. Due to differences between die casting and gravity casting, there are several drawbacks in
RP simulated die casting. This paper is concerned with the development of a new plaster die casting process that combines
pressurization and vibration for prototyping of die castings, and with a plaster die casting machine that has a structure
similar to that of a die casting machine. The machine utilizes an oil cylinder for pressurization and a magnetic actuator
for vibration. A rapid prototyped pattern is made by the laminated object manufacturing (LOM) process to prepare a plaster
mold. In the process, a plunger in the developed machine simultaneously pressurizes and vibrates the molten metal to fill
the plaster mold completely and to facilitate the creation of nuclei in the molten metal, respectively. The developed machine
has produced a prototype of an end clutch cover with remarkable improvement in mechanical properties. |
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Keywords: | Plaster casting Rapid tooling Simulated die casting Vibration effect |
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