Course detail

Additive Technologies in Foundries

FSI-PTSAcad. year: 2020/2021

The basics of working methods and data processing, CAD modelling and 3D technical drawing for castings that were made using the RP method. Division and the main principles of the RP methods. Selected foundry technologies and computer support for making molds including methods for their measuring (scanning) and making corrections (welding, surface working, etc.). The composition and division of production costs and the economy of prototype castings manufacturing.

Learning outcomes of the course unit

Students will acquire the knowledge and skills of 3D modelling (designing and making), rapid prototyping methods (RP), using computer technology for 3D measuring (scanning), numerical simulations of foundry procedures etc. Process management in selected foundry technologies including quality control and composition and production cost management in prototype and serial production.

Prerequisites

Basic knowledge of materials engineering, physics and mathematics necessary for further engineering practice.

Co-requisites

Not applicable.

Recommended optional programme components

Not applicable.

Recommended or required reading

FORD, S., MINSHALL, T. Invited review article: Where and how 3D printing is used in teaching and education. Additive Manufacturing. Volume 25, January 2019, Pages 13 -150. https://doi.org/10.1016/j.addma.2018.10.028 (CS)
GIBSON, I., D. W. ROSEN a B. STUCKER. Additive manufacturing technologies: rapid prototyping to direct digital manufacturing. New York: Springer, c2010. ISBN 1441911200 (CS)
MITCHELL, A. LAFONT, U., HOŁYŃSKA, M.,SEMPRIMOSCHNIG, C. Additive manufacturing - A review of 4D printing and future applications. Additive Manufacturing, Volume 24, December 2018, Pages 606-626. https://doi.org/10.1016/j.addma.2018.10.038 (CS)
WANG, W., STAL, H. W., CONLEY, J. G. Rapid Tooling Guidelines For Sand Casting, Springer, 2010 ISBN 978-1-4419-5730-6. (CS)
CAMPBELL, J. Casting, Butterworth-Heinemann, Oxford, 2000, ISBN 0 7506 1696 2. (CS)
KAUFMAN, H. UGGOWITZER, P. J. Metalurgy and Processing of High-Integrity Light Metal Pressure Castings. Schiele-Schön, 2007, Berlin. ISBN 3-7949-0754-X (CS)
BOLONO, F., ODORIZZI, S. Numerical simulation of Foundry Processes, Program Leonardo da Vinci, 2001 (CS)
Herman, A. a kol. Počítačové simulace ve slévárenství, Vydavatelství ČVUT, 2000 (CS)

Planned learning activities and teaching methods

The subject is taught in the form of lectures where students learn about the basic concepts, principles and theory of a particular discipline. The lectures are supplemented with practical seminars with computer support, CAD modelling and numerical simulation application of foundry processes and metallographic laboratory workshop.

Assesment methods and criteria linked to learning outcomes

The credit is given for an active participation in seminars. The examination consists of a list of questions summarizing the topics covered. It is an oral examination with written preparation

Language of instruction

Czech

Work placements

Not applicable.

Aims

In this subject, students will get acquainted with the preparation and use of data needed for 3D scanning of models and castings, for numerical simulations and virtual engineering. Students will learn about the basic methods and principles of the RAPID PROTOTYPING (RP) technology, including reverse engineering procedures (RE). They will get familiar with the selected modern technologies for manufacturing castings and process management methods with the application of the industry 4.0 principles. They will also learn model surfacing procedures and methods for RP, molds and castings and they will get acquainted with the dimension and shape accuracy testing methods and metallographic and phase casting material assessment methods. Part of the subject will also be to obtain knowledge of the composition of production costs and the foundry production economy.

Specification of controlled education, way of implementation and compensation for absences

Participation in lectures is recommended. Participation in seminars is compulsory. Comprehension is checked in seminars. The tutor gives the students individual tasks. Missed classes need to be discussed with the guarantor.

Classification of course in study plans

  • Programme N-SLE-P Master's, 1. year of study, summer semester, 5 credits, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Teacher / Lecturer

Syllabus

1. Foundry manufacturing processes – the division of manufacturing technologies, information and technological flow in foundries, methods of collecting and analyzing data and information obtained from manufacturing processes.
2. CAD modelling – principles, methods and tools for making 3D model drawings for RP methods and numerical simulations.
3. Reverse engineering methods.
4. Virtual engineering and industry 4.0.
5. Using virtual reality in engineering.
6. Additive technology - Rapid Prototyping (RP) methods – division of RP methods, principles of the different methods.
7. 3D printing technology of metal materials
8. RP methods suitable for foundry processes, examples of its use, reachable parameters.
9. Selected foundry technologies for RP methods and industry 4.0 – precision investment casting process based on lost-wax casting, die casting technology and selected methods of gravity casting in sand molds.
10. Application of robots and robotic workshops for selected manufacturing technologies of die casting and low pressure casting.
11. Surface finishing of models for RP, surface finishing molds for selected modern technologies, correction welding, Cold Spray method.
12. Casting structure and properties assessment – metallographic assessment of casting structure and properties, NDT testing of castings
13. Manufacturing costs of the castings – composition and calculation of costs, cost prediction and management for prototype and serial casting production.

Laboratory exercise

39 hours, compulsory

Teacher / Lecturer

Syllabus

1. - 3. Making 3D casting models and casting models using Solid Works software
4. Making numerical networks of 3D drawings, preparation for numerical simulations
5. - 8. Numerical simulations of the casting production processes – filling, cooling and solidifying simulations, deformation and inner tension simulations
9. - 11. Making 3D models, molds and casting
12. - 13. Quality control of castings, NDT testing and metallographic assessment of the material structure of the castings

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