Optimization Of Casting System For Z-Printed High Temperature Mould Cast Zamak Alloy Via Advanced Simulation Techniques
Manufacturing of sound casting product requires continuous monitoring and maintaining the quality and integrity right from the design to the final production phase. In the development phase, optimizing the mould and runner gating system have key importance. Advanced Casting Simulation facilitates the designers to timely predict and resolve the casting anomalies just at the development phase prior to the actual casting process which saves money, lead time and provides design flexibility as compared to hit and trial method. Substantial factors involve in controlling the overall soundness of casting are: pour temperature and time, mould filling pressure, design of runner gating system and cast part geometry. Optimization of above parameters is important for getting sound casting. In this research MAGMASOFT® casting simulation tool has been utilized for simulating 3D-Z-Printed mould Direct Metal cast technology and to get optimum casting parameters, to cast a critical dimensioned material part from (Zamak 3-having higher viscosity) difficult to cast using conventional gravity casting methods. Advanced Rapid Prototyping Technology has been adopted in this study instead of using conventional sand moulding and casting methods. Use of 3D Z-Printing Technology provides us pattern-less mould making directly from the CAD model with intricate details and close dimensional tolerance which is nearly impossible to get from conventional sand casting method. Main concentration in this paper is to integrate and validate the Rapid Prototyping Technology with the Advanced Casting Simulation technique using the unconventional route of 3D Z-Printing Technology for Rapid Mould making and Direct Casting.
Keywords- Rapid Prototyping; 3D Z-Printing; Direct Casting; Dimensional Tolerance