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D. Benny Karunakar - One of the best experts on this subject based on the ideXlab platform.
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Utility-Fuzzy-Taguchi based hybrid approach in Investment Casting process
International Journal on Interactive Design and Manufacturing (IJIDeM), 2014Co-Authors: Sarojrani Pattnaik, D. Benny Karunakar, P K JhaAbstract:In this paper, the use of the Utility-Fuzzy-Taguchi based hybrid approach in Investment Casting process for optimizing multiple quality characteristics of wax patterns has been conceptualized. Selection of an appropriate orthogonal array, preference scale construction followed by preference values, generation of multi-performance index (MPI) by fuzzy logic, analysis of means and analysis of variance are employed to study the performance characteristics of the process. The control factors considered are injection temperature, injection pressure and injection time, whereas linear shrinkage, surface roughness and penetration are the corresponding responses. The optimal setting obtained by the proposed method is validated by confirmatory experiments. This concludes the application feasibility of the proposed method for parametric optimizations in Investment Casting process. Further, the result of the aforementioned optimization technique has been compared with that of Utility-Taguchi technique. It is found that the optimal condition for both is same, while the most influential process parameter is different in both cases due to employment of random selection of weights in Utility-Taguchi method.
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Enhancement of porosity of the ceramic shell in Investment Casting process using needle coke and camphor
Applied Mechanics and Materials, 2014Co-Authors: Khyati Tamta, D. Benny KarunakarAbstract:Investment Casting process has been a widely used process for centuries. It is known for its ability to produce components of complex shapes with dimensional accuracy and excellent surface finish. Investment Casting has been used to make manufacture weapons, jewellery and art Castings during the ancient civilization and today it is used to manufacture engineering components. In Investment Casting wax patterns are made by wax injection and then coating of the wax patterns are done by ceramic slurry, made with silica flour and binder. After dewaxing and firing molten metal is poured in the shell and solidified Casting can be achieved. Investment Casting can be cast any ferrous and non ferrous metal which is difficult in die Casting. Finishing operations are negligible and very thin sections as.75mm can also be cast which is not possible in sand Casting but there are many challenges in Investment Casting. It is relatively slow process because preparation of ceramic shell consumes a lot of time, permeability of shell is very low which causes gas permeability. Incorporation of chills is very difficult. Among all these challenges gas porosity is main problem because of poor permeability, entrapment of gases due to complex geometry of the shell, reuse of scrap metal. In the present work porosity of the shell can be increase by addition of mixture of Camphor and needle coke. After firing of the shell camphor and needle coke will be burnt leaving pores for the escape of entrapped gases. Mechanical properties of the both shell will be compared with each other.
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A review of rapid prototyping integrated Investment Casting processes
Proceedings of the Institution of Mechanical Engineers Part L: Journal of Materials: Design and Applications, 2013Co-Authors: Sarojrani Pattnaik, D. Benny KarunakarAbstract:Investment Casting is competitive with all other Casting processes where the size of the product is within a mutually castable range. Though Investment Casting is used to produce metal parts of any intricate shapes with excellent surface finish, it suffers from long lead time and high tooling costs, which makes it uneconomical for the production of either single Casting, or small and medium production units. These problems could be overcome by the applications of rapid prototyping and rapid tooling technologies for low-volume Investment Casting production runs. The present article analyzes different classifications of rapid prototyping techniques and it reviews various investigations made on the usability of rapid prototyping- and rapid tooling-integrated Investment Casting process, with their advantages and limitations. The emerging areas of applications of rapid prototyping like dentistry, jewelry, surgical implants, turbine blades, etc., are accordingly discussed. Further, an elaborate discussion is ma...
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Developments in Investment Casting process—A review
Journal of Materials Processing Technology, 2012Co-Authors: Sarojrani Pattnaik, D. Benny KarunakarAbstract:Abstract Investment Casting has been used to manufacture weapons, jewellery and art Castings during the ancient civilization. Today, its applications include jewellery/art Castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of Investment Casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in Investment Casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions. Different investigations carried out on autoclave dewaxing and microwave dewaxing conclude that the wax properties are less altered with microwave dewaxing when compared to an autoclave dewaxing. Some recent investigations carried out on pouring and post-treatment operations are also discussed in the paper. The advent and emergence of rapid prototyping in Investment Casting are broadly exposed in the subsequent sections of the paper. Various aspects of rapid prototyping like rapid Investment Casting, rapid freeze prototyping, etc., along with their advantages are projected. The emerging areas of applications of rapid prototyping like dentistry, etc., are duly discussed.
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Developments in Investment Casting process - A review
Journal of Materials Processing Technology, 2012Co-Authors: Sarojrani Pattnaik, D. Benny Karunakar, P K JhaAbstract:Investment Casting has been used to manufacture weapons, jewellery and art Castings during the ancient civilization. Today, its applications include jewellery/art Castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of Investment Casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in Investment Casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions. Different investigations carried out on autoclave dewaxing and microwave dewaxing conclude that the wax properties are less altered with microwave dewaxing when compared to an autoclave dewaxing. Some recent investigations carried out on pouring and post-treatment operations are also discussed in the paper. The advent and emergence of rapid prototyping in Investment Casting are broadly exposed in the subsequent sections of the paper. Various aspects of rapid prototyping like rapid Investment Casting, rapid freeze prototyping, etc.; along with their advantages are projected. The emerging areas of applications of rapid prototyping like dentistry, etc.; are duly discussed. © 2012 Elsevier B.V. All rights reserved.
Sarojrani Pattnaik - One of the best experts on this subject based on the ideXlab platform.
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Utility-Fuzzy-Taguchi based hybrid approach in Investment Casting process
International Journal on Interactive Design and Manufacturing (IJIDeM), 2014Co-Authors: Sarojrani Pattnaik, D. Benny Karunakar, P K JhaAbstract:In this paper, the use of the Utility-Fuzzy-Taguchi based hybrid approach in Investment Casting process for optimizing multiple quality characteristics of wax patterns has been conceptualized. Selection of an appropriate orthogonal array, preference scale construction followed by preference values, generation of multi-performance index (MPI) by fuzzy logic, analysis of means and analysis of variance are employed to study the performance characteristics of the process. The control factors considered are injection temperature, injection pressure and injection time, whereas linear shrinkage, surface roughness and penetration are the corresponding responses. The optimal setting obtained by the proposed method is validated by confirmatory experiments. This concludes the application feasibility of the proposed method for parametric optimizations in Investment Casting process. Further, the result of the aforementioned optimization technique has been compared with that of Utility-Taguchi technique. It is found that the optimal condition for both is same, while the most influential process parameter is different in both cases due to employment of random selection of weights in Utility-Taguchi method.
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A review of rapid prototyping integrated Investment Casting processes
Proceedings of the Institution of Mechanical Engineers Part L: Journal of Materials: Design and Applications, 2013Co-Authors: Sarojrani Pattnaik, D. Benny KarunakarAbstract:Investment Casting is competitive with all other Casting processes where the size of the product is within a mutually castable range. Though Investment Casting is used to produce metal parts of any intricate shapes with excellent surface finish, it suffers from long lead time and high tooling costs, which makes it uneconomical for the production of either single Casting, or small and medium production units. These problems could be overcome by the applications of rapid prototyping and rapid tooling technologies for low-volume Investment Casting production runs. The present article analyzes different classifications of rapid prototyping techniques and it reviews various investigations made on the usability of rapid prototyping- and rapid tooling-integrated Investment Casting process, with their advantages and limitations. The emerging areas of applications of rapid prototyping like dentistry, jewelry, surgical implants, turbine blades, etc., are accordingly discussed. Further, an elaborate discussion is ma...
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developments in Investment Casting process a review
Journal of Materials Processing Technology, 2012Co-Authors: Sarojrani Pattnaik, Benny D KarunakarAbstract:Abstract Investment Casting has been used to manufacture weapons, jewellery and art Castings during the ancient civilization. Today, its applications include jewellery/art Castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of Investment Casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in Investment Casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions. Different investigations carried out on autoclave dewaxing and microwave dewaxing conclude that the wax properties are less altered with microwave dewaxing when compared to an autoclave dewaxing. Some recent investigations carried out on pouring and post-treatment operations are also discussed in the paper. The advent and emergence of rapid prototyping in Investment Casting are broadly exposed in the subsequent sections of the paper. Various aspects of rapid prototyping like rapid Investment Casting, rapid freeze prototyping, etc., along with their advantages are projected. The emerging areas of applications of rapid prototyping like dentistry, etc., are duly discussed.
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Developments in Investment Casting process—A review
Journal of Materials Processing Technology, 2012Co-Authors: Sarojrani Pattnaik, D. Benny KarunakarAbstract:Abstract Investment Casting has been used to manufacture weapons, jewellery and art Castings during the ancient civilization. Today, its applications include jewellery/art Castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of Investment Casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in Investment Casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions. Different investigations carried out on autoclave dewaxing and microwave dewaxing conclude that the wax properties are less altered with microwave dewaxing when compared to an autoclave dewaxing. Some recent investigations carried out on pouring and post-treatment operations are also discussed in the paper. The advent and emergence of rapid prototyping in Investment Casting are broadly exposed in the subsequent sections of the paper. Various aspects of rapid prototyping like rapid Investment Casting, rapid freeze prototyping, etc., along with their advantages are projected. The emerging areas of applications of rapid prototyping like dentistry, etc., are duly discussed.
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Developments in Investment Casting process - A review
Journal of Materials Processing Technology, 2012Co-Authors: Sarojrani Pattnaik, D. Benny Karunakar, P K JhaAbstract:Investment Casting has been used to manufacture weapons, jewellery and art Castings during the ancient civilization. Today, its applications include jewellery/art Castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of Investment Casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in Investment Casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions. Different investigations carried out on autoclave dewaxing and microwave dewaxing conclude that the wax properties are less altered with microwave dewaxing when compared to an autoclave dewaxing. Some recent investigations carried out on pouring and post-treatment operations are also discussed in the paper. The advent and emergence of rapid prototyping in Investment Casting are broadly exposed in the subsequent sections of the paper. Various aspects of rapid prototyping like rapid Investment Casting, rapid freeze prototyping, etc.; along with their advantages are projected. The emerging areas of applications of rapid prototyping like dentistry, etc.; are duly discussed. © 2012 Elsevier B.V. All rights reserved.
Mohsen Shakeri - One of the best experts on this subject based on the ideXlab platform.
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Integration of reverse engineering and rapid technologies for rapid Investment Casting of gas turbine blades
Virtual and Physical Prototyping, 2011Co-Authors: Mohammad Vaezi, Davood Safaeian, Mohsen ShakeriAbstract:The aim of this research work is to offer a unique procedure of integrated Reverse Engineering (RE) and Additive Manufacturing (AM) technologies through implementation of a comprehensive experimental study to present an extensive comparison between applicable rapid technologies for blade rapid Investment Casting. Different direct and indirect AM techniques were used to produce sacrificial Investment Casting patterns. In addition, an aluminium mould of a blade for wax injection was fabricated using Computer Numerical Control (CNC) machining to compare conventional Investment Casting with the proposed rapid Investment Casting process. Dimensional inspection of cast blades showed that the MultiJet Modelling (MJM) method has the most economic justification and compatibility with blade rapid Investment Casting and it can be considered as an alternative to conventional wax precision CNC machining. On the other hand, sacrificial patterns produced by the Perfactory system showed lower applicability for Investment...
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Integration of reverse engineering and rapid technologies for rapid Investment Casting of gas turbine blades
Virtual & Physical Prototyping, 2011Co-Authors: Mohammad Vaezi, Davood Safaeian, Mohsen ShakeriAbstract:The aim of this research work is to offer a unique procedure of integrated Reverse Engineering (RE) and Additive Manufacturing (AM) technologies through implementation of a comprehensive experimental study to present an extensive comparison between applicable rapid technologies for blade rapid Investment Casting. Different direct and indirect AM techniques were used to produce sacrificial Investment Casting patterns. In addition, an aluminium mould of a blade for wax injection was fabricated using Computer Numerical Control (CNC) machining to compare conventional Investment Casting with the proposed rapid Investment Casting process. Dimensional inspection of cast blades showed that the MultiJet Modelling (MJM) method has the most economic justification and compatibility with blade rapid Investment Casting and it can be considered as an alternative to conventional wax precision CNC machining. On the other hand, sacrificial patterns produced by the Perfactory system showed lower applicability for Investment Casting due to pattern flexibility and difficulties in burn-out step. As for examined rapid tooling technologies, silicone rubber moulding was not a stable technique for small batch fabrication of blade wax patterns. In contrast, the results proved that epoxy resin tooling could make possible new cost-effective approaches for low volume production of gas turbine blades. [ABSTRACT FROM PUBLISHER] Copyright of Virtual & Physical Prototyping is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Mohammad Vaezi - One of the best experts on this subject based on the ideXlab platform.
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Integration of reverse engineering and rapid technologies for rapid Investment Casting of gas turbine blades
Virtual and Physical Prototyping, 2011Co-Authors: Mohammad Vaezi, Davood Safaeian, Mohsen ShakeriAbstract:The aim of this research work is to offer a unique procedure of integrated Reverse Engineering (RE) and Additive Manufacturing (AM) technologies through implementation of a comprehensive experimental study to present an extensive comparison between applicable rapid technologies for blade rapid Investment Casting. Different direct and indirect AM techniques were used to produce sacrificial Investment Casting patterns. In addition, an aluminium mould of a blade for wax injection was fabricated using Computer Numerical Control (CNC) machining to compare conventional Investment Casting with the proposed rapid Investment Casting process. Dimensional inspection of cast blades showed that the MultiJet Modelling (MJM) method has the most economic justification and compatibility with blade rapid Investment Casting and it can be considered as an alternative to conventional wax precision CNC machining. On the other hand, sacrificial patterns produced by the Perfactory system showed lower applicability for Investment...
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Integration of reverse engineering and rapid technologies for rapid Investment Casting of gas turbine blades
Virtual & Physical Prototyping, 2011Co-Authors: Mohammad Vaezi, Davood Safaeian, Mohsen ShakeriAbstract:The aim of this research work is to offer a unique procedure of integrated Reverse Engineering (RE) and Additive Manufacturing (AM) technologies through implementation of a comprehensive experimental study to present an extensive comparison between applicable rapid technologies for blade rapid Investment Casting. Different direct and indirect AM techniques were used to produce sacrificial Investment Casting patterns. In addition, an aluminium mould of a blade for wax injection was fabricated using Computer Numerical Control (CNC) machining to compare conventional Investment Casting with the proposed rapid Investment Casting process. Dimensional inspection of cast blades showed that the MultiJet Modelling (MJM) method has the most economic justification and compatibility with blade rapid Investment Casting and it can be considered as an alternative to conventional wax precision CNC machining. On the other hand, sacrificial patterns produced by the Perfactory system showed lower applicability for Investment Casting due to pattern flexibility and difficulties in burn-out step. As for examined rapid tooling technologies, silicone rubber moulding was not a stable technique for small batch fabrication of blade wax patterns. In contrast, the results proved that epoxy resin tooling could make possible new cost-effective approaches for low volume production of gas turbine blades. [ABSTRACT FROM PUBLISHER] Copyright of Virtual & Physical Prototyping is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
P K Jha - One of the best experts on this subject based on the ideXlab platform.
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Utility-Fuzzy-Taguchi based hybrid approach in Investment Casting process
International Journal on Interactive Design and Manufacturing (IJIDeM), 2014Co-Authors: Sarojrani Pattnaik, D. Benny Karunakar, P K JhaAbstract:In this paper, the use of the Utility-Fuzzy-Taguchi based hybrid approach in Investment Casting process for optimizing multiple quality characteristics of wax patterns has been conceptualized. Selection of an appropriate orthogonal array, preference scale construction followed by preference values, generation of multi-performance index (MPI) by fuzzy logic, analysis of means and analysis of variance are employed to study the performance characteristics of the process. The control factors considered are injection temperature, injection pressure and injection time, whereas linear shrinkage, surface roughness and penetration are the corresponding responses. The optimal setting obtained by the proposed method is validated by confirmatory experiments. This concludes the application feasibility of the proposed method for parametric optimizations in Investment Casting process. Further, the result of the aforementioned optimization technique has been compared with that of Utility-Taguchi technique. It is found that the optimal condition for both is same, while the most influential process parameter is different in both cases due to employment of random selection of weights in Utility-Taguchi method.
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Developments in Investment Casting process - A review
Journal of Materials Processing Technology, 2012Co-Authors: Sarojrani Pattnaik, D. Benny Karunakar, P K JhaAbstract:Investment Casting has been used to manufacture weapons, jewellery and art Castings during the ancient civilization. Today, its applications include jewellery/art Castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of Investment Casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in Investment Casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions. Different investigations carried out on autoclave dewaxing and microwave dewaxing conclude that the wax properties are less altered with microwave dewaxing when compared to an autoclave dewaxing. Some recent investigations carried out on pouring and post-treatment operations are also discussed in the paper. The advent and emergence of rapid prototyping in Investment Casting are broadly exposed in the subsequent sections of the paper. Various aspects of rapid prototyping like rapid Investment Casting, rapid freeze prototyping, etc.; along with their advantages are projected. The emerging areas of applications of rapid prototyping like dentistry, etc.; are duly discussed. © 2012 Elsevier B.V. All rights reserved.
