Investigation of optimum parameters of FDM rapid tooling pattern for sand casting

Tan, Mei Yi (2015) Investigation of optimum parameters of FDM rapid tooling pattern for sand casting. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This project investigates optimum parameters of FDM rapid tooling pattern for sand casting. Sand Casting is a major manufacturing process in manufacturing industries today. However, conventional method of producing sand casting pattern may cause customer to lose faith in the economic view. This is due to conventional manufacturing method has difficulty of producing complex and intricate part either in wood or metal pattern. Hence, it causes longer lead time and also higher production cost. Moreover, casting quality is a main concern for sand casting activities. Inappropriate sand casting mould design will lead to casting defects and more rejection numbers of product. Therefore, conventional manufacturing method of producing sand casting pattern is replaced by Fused Deposition Modeling (FDM). FDM is one of additive manufacturing processes that enable fast, flexible and coat-efficient production of sand casting pattern. Moreover, gating system plays an important role to produce high casting quality. Hence, gating system is analysed in order to obtain optimum design of sand casting mould. Three concept designs are developed using SolidWorks software. In order to select the best design concept, ANSYS software has been chosen to stimulate sand casting mould. Lastly, sand casting process is carried out to validate the results of findings.

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