Krutiš Vladimír, Novosad Pavel, Záděra Antonín, Kaňa Václav
Institute of Manufacturing Technology, Brno University of Technology, 616 69 Brno, Czech Republic.
Institute of Machine and Industrial Design, Brno University of Technology, 616 69 Brno, Czech Republic.
Materials (Basel). 2022 May 26;15(11):3805. doi: 10.3390/ma15113805.
Prototypes and small series production of metal thin-walled components is a field for the use of a number of additive technologies. This method has certain limits related to the size and price of the parts, productivity, or the type of requested material. On the other hand, conventional production methods encounter the limits of shape, which are currently associated with the implementation of optimization methods such as topological optimization or generative design. An effective solution is employing hybrid technology, which combines the advantages of 3D model printing and conventional casting production methods. This paper describes the design of aluminum casting using topological optimization and technological co-design for the purpose of switching to new manufacturing technology. It characterizes the requirements of hybrid technology for the material and properties of the model in relation to the production operations of the investment casting technology. Optical roughness measurement compares the surface quality in a standard wax model and a model obtained by additive manufacturing (AM) of polymethyl methacrylate (PMMA) using the binder jetting method. The surface quality results of the 3D printed model evaluated by measuring the surface roughness are lower than for the standard wax model; however, they still meet the requirements of prototype production technology. The measurements proved that the PMMA model has half the thermal expansion in the measured interval compared to the wax model, which was confirmed by minimal shape deviations in the dimensional analysis.
金属薄壁部件的原型制作和小批量生产是多种增材技术的应用领域。这种方法在零件尺寸和价格、生产率或所需材料类型方面存在一定限制。另一方面，传统生产方法存在形状方面的限制，目前这与拓扑优化或生成式设计等优化方法的实施相关。一种有效的解决方案是采用混合技术，它结合了3D模型打印和传统铸造生产方法的优点。本文描述了为转向新制造技术而使用拓扑优化和工艺协同设计进行铝铸件设计的过程。它针对熔模铸造技术的生产操作，阐述了混合技术对模型材料和性能的要求。光学粗糙度测量比较了标准蜡模和使用粘结剂喷射法对聚甲基丙烯酸甲酯（PMMA）进行增材制造（AM）获得的模型的表面质量。通过测量表面粗糙度评估的3D打印模型的表面质量结果低于标准蜡模；然而，它们仍满足原型生产技术的要求。测量证明，与蜡模相比，PMMA模型在测量区间内的热膨胀率为其一半，这在尺寸分析中的最小形状偏差中得到了证实。
