Assessment of surface finish and dimensional accuracy of tools manufactured by metal casting in rapid prototyping sand moulds

K. Nyembwe, D. J. de Beer, J. G. van der Walt, S. Bhero

Research output: Contribution to journalArticle

6 Citations (Scopus)

Abstract

In this paper, an initial assessment of the quality parameters of the surface finish and dimensional accuracy of tools made by metal casting in rapid prototyping (RP) sand moulds is undertaken. A case study from a local tool room, dealing with the manufacturing of an aluminium die for the lost wax process, is employed. Modern techniques, including surface roughness analysis and three dimensional scanning, are used to determine and understand how each manufacturing step influences the final quality of the cast tool. The best surface finish obtained for the cast die had arithmetic average roughness (Ra) and mean average roughness (Rz) respectively equal to 3.23μm and 11.38μm. In terms of dimensional accuracy, 82% of cast-die points coincided with the Computer Aided Design (CAD) data, which is within the typical tolerances of sand cast products. The investigation shows that mould coating contributes slightly to the improvement of the cast tool surface finish. The study also found that the additive manufacturing of the sand mould was the chief factor responsible for the loss of dimensional accuracy. These findings indicate that machining will always be required to improve the surface finish and the dimensional accuracy of cast tools in RP sand moulds.

Original languageEnglish
Pages (from-to)130-143
Number of pages14
JournalSouth African Journal of Industrial Engineering
Volume23
Issue number3
DOIs
Publication statusPublished - Jan 1 2012

Fingerprint

Metal casting
Rapid prototyping
Sand
Surface roughness
3D printers
Waxes
Computer aided design
Machining
Scanning
Aluminum
Coatings

All Science Journal Classification (ASJC) codes

  • Industrial and Manufacturing Engineering

Cite this

@article{237c12cb34c2434d918b2a0e6457ba2e,
title = "Assessment of surface finish and dimensional accuracy of tools manufactured by metal casting in rapid prototyping sand moulds",
abstract = "In this paper, an initial assessment of the quality parameters of the surface finish and dimensional accuracy of tools made by metal casting in rapid prototyping (RP) sand moulds is undertaken. A case study from a local tool room, dealing with the manufacturing of an aluminium die for the lost wax process, is employed. Modern techniques, including surface roughness analysis and three dimensional scanning, are used to determine and understand how each manufacturing step influences the final quality of the cast tool. The best surface finish obtained for the cast die had arithmetic average roughness (Ra) and mean average roughness (Rz) respectively equal to 3.23μm and 11.38μm. In terms of dimensional accuracy, 82{\%} of cast-die points coincided with the Computer Aided Design (CAD) data, which is within the typical tolerances of sand cast products. The investigation shows that mould coating contributes slightly to the improvement of the cast tool surface finish. The study also found that the additive manufacturing of the sand mould was the chief factor responsible for the loss of dimensional accuracy. These findings indicate that machining will always be required to improve the surface finish and the dimensional accuracy of cast tools in RP sand moulds.",
author = "K. Nyembwe and {de Beer}, {D. J.} and {van der Walt}, {J. G.} and S. Bhero",
year = "2012",
month = "1",
day = "1",
doi = "10.7166/23-3-516",
language = "English",
volume = "23",
pages = "130--143",
journal = "South African Journal of Industrial Engineering",
issn = "1012-277X",
publisher = "South African Institute of Industrial Engineers",
number = "3",

}

Assessment of surface finish and dimensional accuracy of tools manufactured by metal casting in rapid prototyping sand moulds. / Nyembwe, K.; de Beer, D. J.; van der Walt, J. G.; Bhero, S.

In: South African Journal of Industrial Engineering, Vol. 23, No. 3, 01.01.2012, p. 130-143.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Assessment of surface finish and dimensional accuracy of tools manufactured by metal casting in rapid prototyping sand moulds

AU - Nyembwe, K.

AU - de Beer, D. J.

AU - van der Walt, J. G.

AU - Bhero, S.

PY - 2012/1/1

Y1 - 2012/1/1

N2 - In this paper, an initial assessment of the quality parameters of the surface finish and dimensional accuracy of tools made by metal casting in rapid prototyping (RP) sand moulds is undertaken. A case study from a local tool room, dealing with the manufacturing of an aluminium die for the lost wax process, is employed. Modern techniques, including surface roughness analysis and three dimensional scanning, are used to determine and understand how each manufacturing step influences the final quality of the cast tool. The best surface finish obtained for the cast die had arithmetic average roughness (Ra) and mean average roughness (Rz) respectively equal to 3.23μm and 11.38μm. In terms of dimensional accuracy, 82% of cast-die points coincided with the Computer Aided Design (CAD) data, which is within the typical tolerances of sand cast products. The investigation shows that mould coating contributes slightly to the improvement of the cast tool surface finish. The study also found that the additive manufacturing of the sand mould was the chief factor responsible for the loss of dimensional accuracy. These findings indicate that machining will always be required to improve the surface finish and the dimensional accuracy of cast tools in RP sand moulds.

AB - In this paper, an initial assessment of the quality parameters of the surface finish and dimensional accuracy of tools made by metal casting in rapid prototyping (RP) sand moulds is undertaken. A case study from a local tool room, dealing with the manufacturing of an aluminium die for the lost wax process, is employed. Modern techniques, including surface roughness analysis and three dimensional scanning, are used to determine and understand how each manufacturing step influences the final quality of the cast tool. The best surface finish obtained for the cast die had arithmetic average roughness (Ra) and mean average roughness (Rz) respectively equal to 3.23μm and 11.38μm. In terms of dimensional accuracy, 82% of cast-die points coincided with the Computer Aided Design (CAD) data, which is within the typical tolerances of sand cast products. The investigation shows that mould coating contributes slightly to the improvement of the cast tool surface finish. The study also found that the additive manufacturing of the sand mould was the chief factor responsible for the loss of dimensional accuracy. These findings indicate that machining will always be required to improve the surface finish and the dimensional accuracy of cast tools in RP sand moulds.

UR - http://www.scopus.com/inward/record.url?scp=84876090853&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=84876090853&partnerID=8YFLogxK

U2 - 10.7166/23-3-516

DO - 10.7166/23-3-516

M3 - Article

AN - SCOPUS:84876090853

VL - 23

SP - 130

EP - 143

JO - South African Journal of Industrial Engineering

JF - South African Journal of Industrial Engineering

SN - 1012-277X

IS - 3

ER -