Skip to main content
SpringerLink
Log in

Rapid casting of complex impeller based on 3D printing wax pattern and simulation optimization

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Rapid casting is the product of digital, information, and optimization of casting technology. It mainly includes rapid prototyping and virtual manufacturing. In order to shorten the production cycle of a stainless steel closed impeller casting, the wax pattern was made by high impact polystyrene (HIPS) with a selective laser sintering and photosensitive resin with stereolithography (SL). In order to prevent the formation of shrinkage defects, different gating systems designed to examine the molten metal flow and solidification behavior during the pouring and solidification process. The results show that pouring temperature is 1550 °C and pouring speed is 0.75 m/s, which is favorable for filling impeller castings, and can avoid casting defects. The optimized gating system prevented surface shrinkage and interior defects. The optimized gating systems have been verified by experiment, and the rapid casting has been realized based on 3D printing wax pattern and simulation optimization. This rapid casting can reduce processing time and costs, and enhance casting quality in the foundry industry.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Chhabra M, Singh R (2011) Rapid casting solutions: a review. Rapid Prototyp J 17(5):328–350

    Article  Google Scholar 

  2. Collins PK, Leen R, Gibson I (2016) Industry case study: rapid prototype of mountain bike frame section. Virtual Phys Prototyp 11(4):295–303

    Article  Google Scholar 

  3. Wong KK, Ho JY, Leong KC, Wong TN (2016) Fabrication of heat sinks by selective laser melting for convective heat transfer applications. Virtual Phys Prototyp 11(3):159–165

    Article  Google Scholar 

  4. Liu HJ, Fan ZT, Huang NY, Dong XP (2003) A note on rapid manufacturing process of metallic parts based on SLS plastic prototype. J Mater Process Technol 142:710–713

    Article  Google Scholar 

  5. Yao WL, Leu MC (1999) Analysis of shell cracking in investment casting with laser stereolithography patterns. Rapid Prototyp J 5(1):12–20

    Article  Google Scholar 

  6. Bassoli E, Gatto A, Iuliano L, Violante MG (2007) 3D printing technique applied to rapid casting. Rapid Prototyp J 13(3):148–155

    Article  Google Scholar 

  7. Cheah CM, Chua CK, Lee CW, Feng C, Totong K (2005) Rapid prototyping and tooling techniques: a review of applications for rapid investment casting. Int J Adv Manuf Technol 25(3):308–320

    Article  Google Scholar 

  8. Dotchev K, Soe S (2006) Rapid manufacturing of patterns for investment casting: improvement of quality and success rate. Rapid Prototyping J 12(3):156–164

    Article  Google Scholar 

  9. Chen X, Li D, Wu H, Tang Y, Zhao L (2011) Analysis of ceramic shell cracking in stereolithography-based rapid casting of turbine blade. Int J Adv Manuf Technol 55(5–8):447–455

    Article  Google Scholar 

  10. Yang JS, Shi YS, Shen QW, Yan CZ (2009) Selective laser sintering of HIPS and investment casting technology. J Mater Process Technol 209:1901–1908

    Article  Google Scholar 

  11. Thammachot N, Dulyapraphant P, Bohez ELJ (2013) Optimal gating system design for investment casting of sterling silver by computer assisted simulation. Int J Adv Manuf Technol 67:797–810

    Article  Google Scholar 

  12. Zhou JX, Wang M, Yin YJ, Shen X, Chen X, Li W, Zhang DQ (2017) Feed paths and hot spots computation based on a time gradient method in casting. Int J Adv Manuf Technol 93:261–272

    Article  Google Scholar 

  13. Kuo JK, Huang PH, Lai HY, Chen JR (2017) Optimal gating system design for investment casting of 17-4PH stainless steel enclosed impeller by numerical simulation and experimental verification. Int J Adv Manuf Technol 92:1093–1103

    Article  Google Scholar 

  14. Sutaria M, Ravi B (2014) Computation of casting solidification feedpaths using gradient vector method with various boundary conditions. Int J Adv Manuf Technol 75:209–223

    Article  Google Scholar 

  15. Kuo JK, Huang PH, Guo MJ (2017) Removal of CrMo alloy steel components from investment casting gating system using vibration-excited fatigue failure. Int J Adv Manuf Technol 89:101–111

    Article  Google Scholar 

  16. Huang PH, Lin CJ (2015) Computer-aided modeling and experimental verification of optimal gating system design for investment casting of precision rotor. Int J Adv Manuf Technol 79:997–1006

    Article  Google Scholar 

  17. Zhi X, Han Y, Yuan X (2015) Casting process optimization for the impellor of 200ZJA slurry pump. Int J Adv Manuf Technol 77:1703–1710

    Article  Google Scholar 

  18. Zhao J, Yi CL (2015) Optimization of investment casting process for stainless steel impeller with complicated geometry. Chin J Mater Res 29(12):955–960

    Google Scholar 

Download references

Funding

This work was financially supported by The Major State Basic Research Development Program of China (2016YFB0701405) and National Natural Science Foundation of China (51705314, 51771118, U1760110). The authors gratefully acknowledge the financial supports from the National Industrial Basis Improvement Project under Project (TC160A310-12-1) and The 13th Five-year Major Project of Aero Engine and Gas Turbine of China (2017-VII-008). The Science and Technology Committee of Shanghai Municipality (Grant Nos. 16DZ2260602) are gratefully acknowledged.

Author information

Authors and Affiliations

  1. Shanghai Key Lab of Advanced High-temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, 800 Dongchuan RD, Minhang District, Shanghai, 200240, China

    Donghong Wang, Anping Dong, Guoliang Zhu, Da Shu, Fei Li & Baode Sun

  2. State Key Laboratory of Metal Matrix Composites, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Donghong Wang, Anping Dong, Guoliang Zhu, Da Shu, Fei Li & Baode Sun

  3. Materials Genome Initiative Centre, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Da Shu & Baode Sun

  4. School of Materials Engineering, Shanghai University of Engineering Science, Shanghai, 201620, China

    Jinyu Sun

Authors
  1. Donghong Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Anping Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Guoliang Zhu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Da Shu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Jinyu Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Fei Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Baode Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Anping Dong.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, D., Dong, A., Zhu, G. et al. Rapid casting of complex impeller based on 3D printing wax pattern and simulation optimization. Int J Adv Manuf Technol 100, 2629–2635 (2019). https://doi.org/10.1007/s00170-018-2736-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2736-9

Keywords

Search

Navigation