Rapid Prototyping - Vacuum - Investment Casting

Transcription

1 Rapid Prototyping - Vacuum - Investment Casting

2 The document it is a detailed process of the following technologies: 1. Rapid prototyping (using a Stratasys Fortus 400mc) 2. Vacuum Casting (using a MK System) 3. Investment Casting (using a MK Cyclone) By reading this document you will be able to understand and produce your own products. For the purpose of the process multiple test parts were used.

3 The Design First of all it is needed to have a 3D model (Catia V6), and export it as an STL file. The STL file will be analyzed in the INSIGHT software that comes with all Stratasys Fortus Systems. Any of the stl models can be built in many ways to the Fortus using the Insight s tools. So the model for saving material and time can be built in 3 ways. 1. Solid 2. Sparse 3. Sparse double dense (this is a solution that combines both strength and time saving) TEST models for scaling:

4 Scaling the Solid and Sparse models: SPARSE 3D MODELS SOLID 3D MODELS Both of the Solid or Sparse 3D models can be used to Vacuum Casting. Sparse 3D models can be used directly to Investment casting process. Vacuum casting using MK System 1 Investment Casting MK Cyclone Solid or Sparse 3D models can be used WAX or Sparse 3D model can be used Silicon mold method Wax or Plastic Models

5 Analysis of the process There are two ways of producing a PLASTIC or METAL 3D model using both Stratasys and MK Systems Technology. First of all in case there is a need of a Plastic PART, Stratasys Fortus 400mc can build a Direct Digital Manufacture parts. For the purpose of this document we also used the MK System1 to produce a WAX part and Plastic part via silicon mold. In order to have a METAL part MK Cyclone System can use either WAX 3D model from MK SYSTEM 1 via silicon mold, or can use a Sparse 3D model directly from the Stratasys Fortus System. Sparse 3D model from a Fortus System to Cyclone WAX 3D model from MK SYSTEM 1 to Cyclone

6 In this section the Vacuum and Investment casting method will be analyzed. For the purpose of this process the following steps must be followed. 1. 3D model from Stratasys 400mc 2. Preparing the silicon and the WAX for the MK System 1 3. Pouring wax 4. Preparing the Tree for the Cyclone 5. Removing the wax from the Tree using AutoClave 6. Preparing the Burner 7. Pouring aluminum or steel using MF5000 or MF Cleaning and smoothing the models using Sandblaster machines 3D Model from Stratasys 400mc Preparing the silicon mold In this stage we need to be careful and make the appropriate measurements for the model and make the right decisions on the orientation and cutting line of the model. Adding Silicon

7 Silicon molds are ready Preparing the WAX and the tree

8 Preparing the mold for pouring the wax Warming up the silicon mold in the Oven UFE 600

9 Preparing the MK System 1 for Pouring Wax. Removing the silicon mold based on the cutting line.

10 Preparing the MK Cyclone and the trees The tree now is attached the Cyclone s Head

11 Cyclone is preparing the layers from primary and secondary slurry. Filled in with sand Using Infrared light the layers are getting stronger and dry much faster

12 Cyclone moves to the secondary slurry More sand is added Infrared light is drying the cell

13 The cell is ready for dewaxing In between a second tree is prepared this time with sparse 3D models Directly from the Fortus 400mc

14 Wearing thermal protective clothes, the engineer is ready to remove the tree from the Burner. 700 to 800 Degrees Celsius depend on the metal we are going to use for pouring

15 In between there is a time to prepare a second tree mixed with wax 3D model made in a MK System 1 and 3D model parts from the Fortus 400mc. Cyclone has finished the process and the model is ready for Dewaxing.

16 Preparing the MF 3000 and MF5000 for pouring Pouring Metal to the cell

17 Metal is cooled down and the model is ready. Cleaning the model with the Sandblaster machine Testing the model

18 In the meantime engineers prepared a second tree with models that were used directly from the Fortus System to the MK Cyclone. Then the cell was processed to the AutoClave for Dewaxing. Afterburner was well prepared and pouring steel becomes an easy task by taking all the appropriate safety measures.