3dp related lectures

401 ME 3dp tech

ME 401 Digital Sculpture

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Meet in classroom today

Meet in classroom today.

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Links for crucibles

You should buy a silicon carbide or at least a graphite crucible of at least a size number 3.  A bildge shape is usually easier to deal with.

http://www.seattlepotterysupply.com/

http://www.unitedwesternsupply.net/foundry_equipment.nxg

This is the company I usually use:
http://www.mifco.com/MS/catalogmain.html

RioGrande is a jewelry supplier that carries small crucibles:
http://www.riogrande.com/Product/Salamander-Clay-Graphite-No-6-Crucible-20-lbs/704159?pos=12

Expensive, but available:
budgetcastingsupply.com

You can actually find crucibles on amazon.  Here is a graphite #4 for $42
http://www.amazon.com/GRAPHITE-CRUCIBLES-SIZE-4-0/dp/B000HWNSAA/ref=sr_1_12?s=industrial&ie=UTF8&qid=1342767948&sr=1-12

 

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A few links to help you get started.

http://www.backyardmetalcasting.com
http://www.metalcastingzone.com
http://www.artmetal.com
http://www.industrycommunity.com/myforum/lee_seymour/
http://l.webring.com/t/Hobby-Foundry
http://www.metalartistforum.com
http://groups.yahoo.com/group/hobbicast/
http://groups.yahoo.com/search?query=foundry
http://groups.yahoo.com/search?query…sort=relevance

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Sand Casting UPDATED!!!

Below is the lecture on sand that we have covered so far.  One thing that I have noticed, that you all need to consider is in most cases with green sand the mold is poured with the pattern horizontal.  In this case the pattern is centered horizontally in the rectangular mold and fed with a main gate sprue from one side (see cross-section image in last slide).  This main gate will usually then have horizontal channels coming from it that lead to the pattern.  On the opposite side, there are usually channels that lead to vents and risers.

Lecture is updated to include information covered to date.  You will be responsible for the information through the slide on simulation software (I believe that is around slide 100).  Note that some information about aluminum has been added at to the lecture, you are also responsible for this information as well.

 

401 Sand Casting

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A few ideas for research paper

Anything involving the history of casting – what type of molds, furnaces and metal alloys were used during a specific time?  What were the advantages and disadvantages of this process/material?  How can some of this knowledge be applied to modern casting?  Wootz is one interesting topic in this venue as is the study of the development of steel (what is the Bessemer process and how did it change the world?).  Viking casting methods, Egyptian casting methods, Roman casting methods, Renaissance Casting  Benin casting methods etc.  The early documents published in India about casting could be very interesting to explore.

Research on other furnace types – we have gone over several but there are many that we have not touched on or won’t even be able to get into carbon arc furnaces, induction furnaces, blast furnaces etc.

Researching other mold forms that we have not yet been able to touch upon resin-bonded molds, die-cast molding, vacuum casting, centrifugal casting or conducting a deep level of research on one of the mold types that is in existence already.

Of course, especially for the 3D printing club – researching additive manufacturing applications for metal casting is a no brainer.   Even asking questions as to whether or not a foundry is going to be prevalent in the age of rapid manufacturing (I think it is, hopefully for obvious reasons – but I do not think any foundry is going to survive without adopting 3DP tech).

The American Foundry Society can be an amazing resource for ideas.  They even have an android app that you can download to read their magazines.

What are the major casting flaws and their causes?

What are the different properties of non-ferrous metals?  Why would you use one type of steel in a casting vs. another?

What are the environmental concerns with casting and what can be done to reduce the impact of metal casting on the environment?

Safe vs. unsafe foundry practice

Good designs for foundries – considering human factors engineering (if you have not guesses this is one of my many interests)

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Ceramic Shell Patterns

Original pattern should be group designed. Should have a function without it being obvious. Your team should submit 4 variations on this theme – with slight variation among two pairs and more extreme variation in the pair of pairs. This is an exercise in the use of digital tech to develop an idea. The form should not be larger than 5x3x2 inches (smaller is ok) and no thinner than 1/4 inch. You should avoid multiple changes in direction, as you must be able to reach the interior of the entire pattern with a thin wire. The firm should be submitted to scale via email in STL format. Any file not submitted to scale will not be printed.

Continue reading

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Ceramic Shell Casting Process

Link to lecture on ceramic shell. Note the lecture  contains additional information that you will be responsible for.

 

401 Ceramic Shell

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Traditional lost wax clay molds and crucible pour

The images that follow describe the process that has been used for over 3000 years to create lost wax castings.  The furnace is a contemporary design propane fired gas furnace.

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tomorrow and pour

If you can, please meet at 9am in the morning.  Those that come early will have their mold poured first and get first priority on being on the team.

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