The Experts below are selected from a list of 360 Experts worldwide ranked by ideXlab platform
Rupinder Singh - One of the best experts on this subject based on the ideXlab platform.
-
mathematical modelling of surface roughness for vapour processing of abs parts fabricated with fused deposition modelling
Journal of Manufacturing Processes, 2016Co-Authors: Jasgurpreet Singh Chohan, Rupinder Singh, Kamaljit Singh BoparaiAbstract:Abstract Fused deposition modelling (FDM) has number of applications in the field of Metal Casting but the poor surface finish acts as major obstruction against rapid investment Casting of the replicas prepared by this process. The vapour smoothing (VS) has proved to be promising technique as fine details of parts are preserved due to absence of tool-work piece contact and mechanical force. In the present study, the outcome of Taguchi and ANOVA analysis has been used to develop a mathematical model for average surface roughness of vapour treated parts prepared by FDM. The relationship between six input parameters, two of FDM and four of VS has been derived using Buckingham's Pi theorem. The study explored the effect of smoothing time and number of cycles on surface roughness and as confirmed by statistical analysis. The model gives output in form of percentage change in surface roughness as a function of smoothing time and number of cycles where final roughness of vapour exposed FDM parts can be predicted.
-
Mathematical Modeling of Surface Roughness of Castings Produced Using ZCast Direct Metal Casting
Journal of The Institution of Engineers (India): Series C, 2015Co-Authors: Munish Chhabra, Rupinder SinghAbstract:Aim of this investigation is to develop a mathematical model for predicting surface roughness of Castings produced using ZCast process by employing Buckingham’s ?-theorem. A relationship has been proposed between surface roughness of Castings and shell wall thickness of the shell moulds fabricated using 3D printer. Based on model, experiments were performed to obtain the surface roughness of aluminium, brass and copper Castings produced using ZCast process based on 3D printing technique. Based on experimental data, three best fitted third-degree polynomial equations have been established for predicting the surface roughness of Castings. The predicted surface roughness values were then calculated using established best fitted equations. An error analysis was performed to compare the experimental and predicted data. The average prediction errors obtained for aluminium, brass and copper Castings are 10.6, 2.43 and 3.12 % respectively. The obtained average surface roughness (experimental and predicted) values of Castings produced are acceptable with the sand cast surface roughness values range (6.25–25 µm).
-
obtaining desired surface roughness of Castings produced using zcast direct Metal Casting process through taguchi s experimental approach
Rapid Prototyping Journal, 2012Co-Authors: Munish Chhabra, Rupinder SinghAbstract:Purpose – The purpose of this paper is to investigate experimentally the effect of volume of Casting, pouring temperature of different materials and shell mould wall thickness on the surface roughness of the Castings obtained by using ZCast direct Metal Casting process.Design/methodology/approach – Taguchi's design of experiment approach was used for this investigation. An L9 orthogonal array (OA) of Taguchi design which involves nine experiments for three factors with three levels was used. Analysis of variance (ANOVA) was then performed on S/N (signal‐to‐noise) ratios to determine the statistical significance and contribution of each factor on the surface roughness of the Castings. The Castings were obtained using the shell moulds fabricated with the ZCast process and the surface roughness of Castings was measured by using the surface roughness tester.Findings – Taguchi's analysis results showed that pouring temperature of materials was the most significant factor in deciding the surface roughness of th...
Munish Chhabra - One of the best experts on this subject based on the ideXlab platform.
-
Mathematical Modeling of Surface Roughness of Castings Produced Using ZCast Direct Metal Casting
Journal of The Institution of Engineers (India): Series C, 2015Co-Authors: Munish Chhabra, Rupinder SinghAbstract:Aim of this investigation is to develop a mathematical model for predicting surface roughness of Castings produced using ZCast process by employing Buckingham’s ?-theorem. A relationship has been proposed between surface roughness of Castings and shell wall thickness of the shell moulds fabricated using 3D printer. Based on model, experiments were performed to obtain the surface roughness of aluminium, brass and copper Castings produced using ZCast process based on 3D printing technique. Based on experimental data, three best fitted third-degree polynomial equations have been established for predicting the surface roughness of Castings. The predicted surface roughness values were then calculated using established best fitted equations. An error analysis was performed to compare the experimental and predicted data. The average prediction errors obtained for aluminium, brass and copper Castings are 10.6, 2.43 and 3.12 % respectively. The obtained average surface roughness (experimental and predicted) values of Castings produced are acceptable with the sand cast surface roughness values range (6.25–25 µm).
-
obtaining desired surface roughness of Castings produced using zcast direct Metal Casting process through taguchi s experimental approach
Rapid Prototyping Journal, 2012Co-Authors: Munish Chhabra, Rupinder SinghAbstract:Purpose – The purpose of this paper is to investigate experimentally the effect of volume of Casting, pouring temperature of different materials and shell mould wall thickness on the surface roughness of the Castings obtained by using ZCast direct Metal Casting process.Design/methodology/approach – Taguchi's design of experiment approach was used for this investigation. An L9 orthogonal array (OA) of Taguchi design which involves nine experiments for three factors with three levels was used. Analysis of variance (ANOVA) was then performed on S/N (signal‐to‐noise) ratios to determine the statistical significance and contribution of each factor on the surface roughness of the Castings. The Castings were obtained using the shell moulds fabricated with the ZCast process and the surface roughness of Castings was measured by using the surface roughness tester.Findings – Taguchi's analysis results showed that pouring temperature of materials was the most significant factor in deciding the surface roughness of th...
Li Lu - One of the best experts on this subject based on the ideXlab platform.
-
direct laser sintering of a silica sand
Materials & Design, 2003Co-Authors: Y Tang, Y S Wong, Li LuAbstract:As an application study of rapid prototyping, commercially available silica sand was successfully direct-laser-sintered in a self-developed high-temperature laser sintering equipment. The mechanism of powder-state sand becoming a solid state block during the laser sintering process was disclosed by scanning electron microscope (SEM) and energy dispersive X-ray (EDX) analysis on sand particles and sintered samples. The effect of process parameters to the accuracy, strength and surface finish of sintered parts was investigated and thus a set of optimal parameters has been obtained for the sand sintering process. The feasibility of using this material and process to build Casting moulds for Metal Casting was also investigated and discussed.
Guha P. Manogharan - One of the best experts on this subject based on the ideXlab platform.
-
Novel sprue designs in Metal Casting via 3D sand-printing
Additive Manufacturing, 2019Co-Authors: Santosh Reddy Sama, Tony Badamo, Paul Lynch, Guha P. ManogharanAbstract:The opportunity to improve the quality of Metal Castings by enabling fabrication of complex gating systems via 3D Sand-Printing (3DSP) has been recently established. Among the different components of a gating system (often called rigging), sprue design offers a major opportunity to exploit the unlimited geometric freedom offered by 3DSP process. In this study, conventional principles of Casting hydrodynamics is advanced by validated novel numerical models for novel sprue designs to improve melt flow control. Computational flow simulations demonstrate that conical-helix sprue satisfy the critical velocity condition by reducing the ingate velocity below 0.5 m/s. Multiple approaches to integrate 3DSP into conventional manufacturing to fabricate complex gating systems through “Hybrid Molding” are presented. 3DSP molds featuring two optimized sprue profiles and a benchmark straight sprue are fabricated to pour 17-4 stainless steel. Computed tomography scans (CT) shows that parabolic sprue Casting (PSC) and conical-helix sprue Casting (CHSC) reduced overall Casting defects by 56% and 99.5% respectively when compared to straight sprue Casting (SSC). Scanning electron microscopy (SEM) analysis confirms the presence of globular oxide inclusions and that PSC and CHSC exhibits 21% and 35% reduced inclusion when compared to the SSC. Three point flexural testing reveals that CHSC and PSC exhibits an increase of 8.4% and 4.1% respectively in average ultimate flexural strength than SSC. The findings from this study demonstrate that numerically optimized gating systems that can only be fabricated via 3DSP have the potential to significantly improve both mechanical and Metallurgical performance of sand Castings.
-
Non-conventional mold design for Metal Casting using 3D sand-printing
Journal of Manufacturing Processes, 2018Co-Authors: Santosh Reddy Sama, Jiayi Wang, Guha P. ManogharanAbstract:3D Sand-Printing (3DSP) is a relatively new Additive Manufacturing (AM) technology that enables direct digital manufacturing (DDM) of complex sand molds and cores for sand Casting applications. Ever-growing interest in this indirect hybrid Metal AM process is attributed to its ability to rapidly produce tooling (i.e., cores and molds) for complex Metal Castings that are otherwise impossible to manufacture using conventional techniques. Knowledge-based design rules for this process is currently very limited and is being progressively realized on an ad-hoc basis to produce economicaly viable low-batch Castings. In this research, non-conventional design rules for gating and feeding (also known as rigging) is developed to improve Casting performance (i.e., filling, feeding and solidification). Several case studies are presented to illustrate the improved Casting performance by systematically redesigning each element of the rigging system. Computational simulations of the melt flow are developed to evaluate the effectiveness of redesigned rigging system. This research further illustrates the ability of 3DSP to not only impact part performance, i.e., optimized Metal Casting designs via 3DSP but also drastically improves the Casting performance which could potentially transform the industry of sand Casting to produce high quality Castings.
Y Tang - One of the best experts on this subject based on the ideXlab platform.
-
direct laser sintering of a silica sand
Materials & Design, 2003Co-Authors: Y Tang, Y S Wong, Li LuAbstract:As an application study of rapid prototyping, commercially available silica sand was successfully direct-laser-sintered in a self-developed high-temperature laser sintering equipment. The mechanism of powder-state sand becoming a solid state block during the laser sintering process was disclosed by scanning electron microscope (SEM) and energy dispersive X-ray (EDX) analysis on sand particles and sintered samples. The effect of process parameters to the accuracy, strength and surface finish of sintered parts was investigated and thus a set of optimal parameters has been obtained for the sand sintering process. The feasibility of using this material and process to build Casting moulds for Metal Casting was also investigated and discussed.