Part Buyers Authority Issue #4

13 Visit partbuyersauthority.com to SUBSCRIBE o r CONTRIBUTE as an author. SOLIDIFICATION SIMULATION Like fluid flow simulation, solidification simulation allows a foundry engineer to predict the location of casting shrinkage porosity. Understanding the location of casting porosity allows the foundry engineer to design and optimize the casting’s manufacturing method. In short, foundry simulation can help significantly reduce casting lead time by making design “mistakes” on a computer rather than the foundry production floor. Contact: MARTY RENK [email protected] LASER METROLOGY Laser Metrology, or laser scanning, uses light to measure objects. When applied to a DC, laser scanning is used to compare the DC against a CAD solid model. The laser scan data is overlaid to the CAD solid model and the foundry engineer can compare dimensional discrepancies in the DC. A color map is used as a visual reference to show the DC’s dimensional accuracy. DC’s offer many advantages to the casting buyer and casting user. DC’s can be used for rapid prototypes, supporting a legacy product line, short production runs or provide the foundation for a first article casting. A key consideration when looking to procure a DC, however, is finding an integrated DC technology service provider. Piecemealing DC services by using multiple vendors, who don’t offer a complete solution, can prove to be troublesome. A fragmented approach can foster finger pointing when things don’t go as expected, can lengthen lead times, and ultimately add cost to the casting. to fill the patternmaking skills gap. Fused Deposition Modeling (FDM) is a 3D printing technique which builds an object by extruding plastic through a computer-controlled machine. 3D printed tooling offers several advantages over traditionally built patterns; improved speed, reduced cost, design optimization and moderate tool life. 1. Improved Speed 3D printers can run around the clock. Some FDM printers use multiple extruder heads, thereby printing parallel and reducing print time. 2. Reduced Cost FDM printers are relatively low- cost machines and simple to maintain. 3. Design Optimization 3D printing allows a casting design to be adjusted quickly and cost effectively. In some cases, designs can be tweaked, 3D printed and recast in as fast as 24 – 48 hours. 4. Moderate Tool Life Many domestic foundries would be considered job shops who produce low to moderate volume/high product mix castings. The life of an FDM 3D printed tool can offer a life ranging from one mold to thousands of molds. 3D PRINTING Traditionally, foundry tooling has been made by skilled craftsmen, called patternmakers, using various wood working equipment and tools. Unfortunately, over the past 10 years the number of patternmakers entering the trade has declined. In recent years, the application of 3D printers has been used