The Experts below are selected from a list of 3480 Experts worldwide ranked by ideXlab platform
Jouke C. Verlinden - One of the best experts on this subject based on the ideXlab platform.
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life cycle assessment of wire arc additive manufacturing compared to green Sand Casting and cnc milling in stainless steel
Journal of Cleaner Production, 2018Co-Authors: Anne C.m. Bekker, Jouke C. VerlindenAbstract:Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing technique based on robotic welding. This technique yields potential in decreasing material consumption due to its high material efficiency and freedom of shape. Empirical measurements of WAAM, using a deposition rate of 1 kg/h, were performed on site of MX3D. The measured power consumption per kg stainless steel is 2.72 kW, of which 1.74 is consumed by the welder, 0.44 by the robotic arm, and 0.54 by the ventilation. The material loss was 1.1%. A 98% argon 2% CO2 welding gas was used with a flow of 12 l/min. A cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this assessment context, green Sand Casting and CNC milling were additionally assessed, through literature and databases. The purpose of this study is to develop insight into the environmental impact of WAAM. Results indicate that, in terms of total ReCiPe endpoints, the environmental impact of producing a kg of stainless steel 308 l product using WAAM is comparable to green Sand Casting. It equals CNC milling with a material utilization fraction of 0.75. Stainless steel is the main cause of environmental damage in all three techniques, emphasizing the importance of WAAM's mass reduction potential. When environmentally comparing the three techniques for fulfilling a certain function, optimized designs should be introduced for each manufacturing technique. Results can vary significantly based on product shape, function, materials, and process settings.
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Life cycle assessment of wire + arc additive manufacturing compared to green Sand Casting and CNC milling in stainless steel
Journal of Cleaner Production, 2018Co-Authors: Anne C.m. Bekker, Jouke C. VerlindenAbstract:Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing technique based on robotic welding. This technique yields potential in decreasing material consumption due to its high material efficiency and freedom of shape. Empirical measurements of WAAM, using a deposition rate of 1 kg/h, were performed on site of MX3D. The measured power consumption per kg stainless steel is 2.72 kW, of which 1.74 is consumed by the welder, 0.44 by the robotic arm, and 0.54 by the ventilation. The material loss was 1.1%. A 98% argon 2% CO2 welding gas was used with a flow of 12 l/min. A cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this assessment context, green Sand Casting and CNC milling were additionally assessed, through literature and databases. The purpose of this study is to develop insight into the environmental impact of WAAM. Results indicate that, in terms of total ReCiPe endpoints, the environmental impact of producing a kg of stainless steel 308 l product using WAAM is comparable to green Sand Casting. It equals CNC milling with a material utilization fraction of 0.75. Stainless steel is the main cause of environmental damage in all three techniques, emphasizing the importance of WAAM's mass reduction potential. When environmentally comparing the three techniques for fulfilling a certain function, optimized designs should be introduced for each manufacturing technique. Results can vary significantly based on product shape, function, materials, and process settings.
Anne C.m. Bekker - One of the best experts on this subject based on the ideXlab platform.
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life cycle assessment of wire arc additive manufacturing compared to green Sand Casting and cnc milling in stainless steel
Journal of Cleaner Production, 2018Co-Authors: Anne C.m. Bekker, Jouke C. VerlindenAbstract:Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing technique based on robotic welding. This technique yields potential in decreasing material consumption due to its high material efficiency and freedom of shape. Empirical measurements of WAAM, using a deposition rate of 1 kg/h, were performed on site of MX3D. The measured power consumption per kg stainless steel is 2.72 kW, of which 1.74 is consumed by the welder, 0.44 by the robotic arm, and 0.54 by the ventilation. The material loss was 1.1%. A 98% argon 2% CO2 welding gas was used with a flow of 12 l/min. A cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this assessment context, green Sand Casting and CNC milling were additionally assessed, through literature and databases. The purpose of this study is to develop insight into the environmental impact of WAAM. Results indicate that, in terms of total ReCiPe endpoints, the environmental impact of producing a kg of stainless steel 308 l product using WAAM is comparable to green Sand Casting. It equals CNC milling with a material utilization fraction of 0.75. Stainless steel is the main cause of environmental damage in all three techniques, emphasizing the importance of WAAM's mass reduction potential. When environmentally comparing the three techniques for fulfilling a certain function, optimized designs should be introduced for each manufacturing technique. Results can vary significantly based on product shape, function, materials, and process settings.
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Life cycle assessment of wire + arc additive manufacturing compared to green Sand Casting and CNC milling in stainless steel
Journal of Cleaner Production, 2018Co-Authors: Anne C.m. Bekker, Jouke C. VerlindenAbstract:Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing technique based on robotic welding. This technique yields potential in decreasing material consumption due to its high material efficiency and freedom of shape. Empirical measurements of WAAM, using a deposition rate of 1 kg/h, were performed on site of MX3D. The measured power consumption per kg stainless steel is 2.72 kW, of which 1.74 is consumed by the welder, 0.44 by the robotic arm, and 0.54 by the ventilation. The material loss was 1.1%. A 98% argon 2% CO2 welding gas was used with a flow of 12 l/min. A cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this assessment context, green Sand Casting and CNC milling were additionally assessed, through literature and databases. The purpose of this study is to develop insight into the environmental impact of WAAM. Results indicate that, in terms of total ReCiPe endpoints, the environmental impact of producing a kg of stainless steel 308 l product using WAAM is comparable to green Sand Casting. It equals CNC milling with a material utilization fraction of 0.75. Stainless steel is the main cause of environmental damage in all three techniques, emphasizing the importance of WAAM's mass reduction potential. When environmentally comparing the three techniques for fulfilling a certain function, optimized designs should be introduced for each manufacturing technique. Results can vary significantly based on product shape, function, materials, and process settings.
Henry W. Stoll - One of the best experts on this subject based on the ideXlab platform.
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Sand Casting Dimensional Control
Mechanical Engineering Series, 2009Co-Authors: Wanlong Wang, Henry W. Stoll, James G. ConleyAbstract:Dimensional accuracy and variability are critical factors in the Casting process that must be considered at each stage of the process. Dimensional accuracy is an indication of how close a Casting dimension is to design intent (the actual target value). Dimensional accuracy is often referred as a system error. The main causes for poor dimensional accuracy in Sand Casting are pattern equipment errors, pattern wear, and Casting contraction uncertainty. When properly understood and controlled, system error can often be corrected before production runs. Dimensional variability is the variation of individual Casting dimensions about their mean. Dimensional variability is often referred to as random error. Many foundry process variables such as placement of cores and Sand consistency contribute to dimensional variability.
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Tool Design and Construction for Sand Casting
Mechanical Engineering Series, 2009Co-Authors: Wanlong Wang, Henry W. Stoll, James G. ConleyAbstract:Typically, the Sand-Casting tool design and fabrication process begins when the tool builder receives the part design from the client or design engineer. In general, the part design can be communicated in variety of ways such as by a physical part, a 2D engineering drawing, a 3D computer generated solid model, or other means that sufficiently conveys the design intent needed for tooling design and fabrication.
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Sand Casting Processes
Mechanical Engineering Series, 2009Co-Authors: Wanlong Wang, Henry W. Stoll, James G. ConleyAbstract:Sand Casting is a mold based net shape manufacturing process in which metal parts are molded by pouring molten metal into a cavity. The mold cavity is created by withdrawing a pattern from Sand that has been packed around it. Since the pattern imprint forms the cavity, the pattern creates the external shape of the cast part. If the part has undercuts or hollow internal regions, these can be formed by Sand cores that are fabricated separately and then placed in the mold cavity. The cores are supported by core prints, and/or chaplets that allow the molten metal to flow between the core and the mold wall. In addition, cores may be necessary to produce a desired “zero” draft external surface, depending on the parting line selected. The parting line is formed by the interface between the cope (upper portion) and drag (lower portion) of the mold. The separate cope and drag are necessary to allow the pattern to be withdrawn from the Sand and to allow the cores to be properly positioned within the mold.
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Rapid tooling for Sand Casting using laminated object manufacturing process
Rapid Prototyping Journal, 1999Co-Authors: Wanlong Wang, James G. Conley, Henry W. StollAbstract:It is now possible to generate tooling for near net shape manufacturing processes directly from a CAD database by using computer numerical control (CNC) machining or a variety of rapid prototyping (RP) processes. These methods are widely referred to as rapid tooling processes because the tool geometry is created in a relatively short time. In particular, the use of RP processes has proved to be a cost‐effective and time‐efficient approach for producing patterns and core boxes for Sand Casting. However, the suitability of this approach depends on a variety of geometry and process related considerations. Investigates the use of the laminated object manufacturing (LOM) based rapid tooling process in Sand Casting. Issues discussed include geometry considerations, error sources and propagation, and shrinkage effects. A case study illustrating time and cost savings using the LOM approach is also presented.
A. Kumaravadivel - One of the best experts on this subject based on the ideXlab platform.
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Theory of inventive problem solving method in Sand Casting process optimisation
International Journal of Productivity and Quality Management, 2015Co-Authors: A. KumaravadivelAbstract:Optimisation of Sand Casting process involves the adjustment of parameters as well as the improvement of optimisation process procedures and measures. Analysis of various critical process parameters and the interaction among them is carried out with the help of Taguchis method of experimental design, response surface methodology (RSM). This paper proposes a Theory of Inventive Problem Solving (TRIZ) method based on the process window approach (PWA) is to make the analysis more precise, cost effective and evaluating the robustness of a process set up quickly. The successful Sand Casting process parameters optimisation demonstrates the feasibility of the proposed method. The objective of this article is to provide foundry personnel with innovative design ideas under research and for practical application.
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optimization of Sand Casting process variables a process window approach
The International Journal of Advanced Manufacturing Technology, 2013Co-Authors: A. Kumaravadivel, U NatarajanAbstract:The present competitive market focuses on producing high-quality products with the lowest possible cost. To help accomplish this objective, various quality-enhanced tools have been put forward in recent years and, of these, process window approach (PWA) has emerged as perhaps the most viable and efficient technique for process quality improvement. The PWA is a powerful tool for quickly optimizing and confirming the quality and robustness of a process setup for any parameters. The work in this paper focuses on implementing a proposed PWA in order to optimize the Sand-Casting operation variables. In this research, the authors have kept their prime focus on minimizing the defects developed in the Sand-Casting process by PWA. Analysis of various critical process parameters and the interaction among them is carried out with the help of Taguchi method of experimental design. To optimize the results obtained and to make the analysis more precise and cost-effective, response surface methodology (RSM) is also incorporated. The optimized parameters obtained using the Taguchi method and RSM are then tested in an industrial case study. It is validated by proposed process window approach.
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Optimization of Sand-Casting process variables—a process window approach
The International Journal of Advanced Manufacturing Technology, 2013Co-Authors: A. Kumaravadivel, U NatarajanAbstract:The present competitive market focuses on producing high-quality products with the lowest possible cost. To help accomplish this objective, various quality-enhanced tools have been put forward in recent years and, of these, process window approach (PWA) has emerged as perhaps the most viable and efficient technique for process quality improvement. The PWA is a powerful tool for quickly optimizing and confirming the quality and robustness of a process setup for any parameters. The work in this paper focuses on implementing a proposed PWA in order to optimize the Sand-Casting operation variables. In this research, the authors have kept their prime focus on minimizing the defects developed in the Sand-Casting process by PWA. Analysis of various critical process parameters and the interaction among them is carried out with the help of Taguchi method of experimental design. To optimize the results obtained and to make the analysis more precise and cost-effective, response surface methodology (RSM) is also incorporated. The optimized parameters obtained using the Taguchi method and RSM are then tested in an industrial case study. It is validated by proposed process window approach.
Wanlong Wang - One of the best experts on this subject based on the ideXlab platform.
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Sand Casting Dimensional Control
Mechanical Engineering Series, 2009Co-Authors: Wanlong Wang, Henry W. Stoll, James G. ConleyAbstract:Dimensional accuracy and variability are critical factors in the Casting process that must be considered at each stage of the process. Dimensional accuracy is an indication of how close a Casting dimension is to design intent (the actual target value). Dimensional accuracy is often referred as a system error. The main causes for poor dimensional accuracy in Sand Casting are pattern equipment errors, pattern wear, and Casting contraction uncertainty. When properly understood and controlled, system error can often be corrected before production runs. Dimensional variability is the variation of individual Casting dimensions about their mean. Dimensional variability is often referred to as random error. Many foundry process variables such as placement of cores and Sand consistency contribute to dimensional variability.
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Tool Design and Construction for Sand Casting
Mechanical Engineering Series, 2009Co-Authors: Wanlong Wang, Henry W. Stoll, James G. ConleyAbstract:Typically, the Sand-Casting tool design and fabrication process begins when the tool builder receives the part design from the client or design engineer. In general, the part design can be communicated in variety of ways such as by a physical part, a 2D engineering drawing, a 3D computer generated solid model, or other means that sufficiently conveys the design intent needed for tooling design and fabrication.
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Sand Casting Processes
Mechanical Engineering Series, 2009Co-Authors: Wanlong Wang, Henry W. Stoll, James G. ConleyAbstract:Sand Casting is a mold based net shape manufacturing process in which metal parts are molded by pouring molten metal into a cavity. The mold cavity is created by withdrawing a pattern from Sand that has been packed around it. Since the pattern imprint forms the cavity, the pattern creates the external shape of the cast part. If the part has undercuts or hollow internal regions, these can be formed by Sand cores that are fabricated separately and then placed in the mold cavity. The cores are supported by core prints, and/or chaplets that allow the molten metal to flow between the core and the mold wall. In addition, cores may be necessary to produce a desired “zero” draft external surface, depending on the parting line selected. The parting line is formed by the interface between the cope (upper portion) and drag (lower portion) of the mold. The separate cope and drag are necessary to allow the pattern to be withdrawn from the Sand and to allow the cores to be properly positioned within the mold.
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Rapid tooling for Sand Casting using laminated object manufacturing process
Rapid Prototyping Journal, 1999Co-Authors: Wanlong Wang, James G. Conley, Henry W. StollAbstract:It is now possible to generate tooling for near net shape manufacturing processes directly from a CAD database by using computer numerical control (CNC) machining or a variety of rapid prototyping (RP) processes. These methods are widely referred to as rapid tooling processes because the tool geometry is created in a relatively short time. In particular, the use of RP processes has proved to be a cost‐effective and time‐efficient approach for producing patterns and core boxes for Sand Casting. However, the suitability of this approach depends on a variety of geometry and process related considerations. Investigates the use of the laminated object manufacturing (LOM) based rapid tooling process in Sand Casting. Issues discussed include geometry considerations, error sources and propagation, and shrinkage effects. A case study illustrating time and cost savings using the LOM approach is also presented.
