SAND CASTING: CONVENTIONAL AND RAPID PROTOTYPING MANUFACTURING APPROACHES

Abstract

Sand casting provides an economic method for mass production of complex and intricate features of metal parts. Manufacturing of moulds to cast small and medium type products involve relatively long lead time and high tooling costs. The application of Rapid Prototyping (RP) technologies to fabricate complex sacrificial patterns can result significant reduction in the cost and lead time associated with the manufacture of single, small or medium quantity productions. Previously this technology was used to develop a model of products. The current research work involves fabrication of pattern using Rapid Prototyping technique and same is used to produce metal castings. A comparison study has been done in the sense of lead time, dimensional accuracy, surface quality and cost investment of patterns and castings produced using RP technique and conventional method (using wooden pattern). It was observed that the patterns produced by the RP Technique have higher dimensional accuracy, good surface finish and nominal cost investment. Also the castings produced by this technique have dimensions, surface quality similar to that of pattern produced by this technique. It also reduces the manufacturing lead time.