Skip to main content
SpringerLink
Log in

A comparative study of fabrication of sand casting mold using additive manufacturing and conventional process

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

Abstract

In this study, two processes to fabricate casting mold, conventional sand casting process and additive manufacturing or 3D printing process, are comparatively investigated. The two processes were compared in terms of their weight saving, surface finish, design allowance, and fettling work. The results show that there are significant advantages in using additive manufacturing in the production of mold. The 3D printed molds provide substantial saving of sand used, design allowances, and fettling work. The mechanical properties of 3D printed molds are also higher than the conventional ones due to good bonding strength during 3D printing.

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. Banchhor R, Ganguly S (2014) Optimization in green sand casting process for efficient, economical and quality casting. Int J Adv Engg Tech/Vol V/Issue I/Jan-March 25:29

    Google Scholar 

  2. Beeley P (2001) Foundry Technology (Second Edition). 2 ed. Butterworth-Heinemann, Oxford, p 719

    Google Scholar 

  3. Campbell J (2003) Castings. 2. ed. Butterworth Heinemann, Burlington 352p

    Google Scholar 

  4. Wang W, Stoll HW, Conley JG (2010) Rapid tooling guidelines for sand casting. 1 ed. In: Mechanical Engineering Series. Springer US, New York XIV, 164

    Google Scholar 

  5. Kalpakjian S, Schmid S (2008) Manufacturing processes for engineering materials. 5th ed. Pearson education, London 1040pp

    Google Scholar 

  6. Meisel, N.A., C.B. Williams, and A. Druschitz. Lightweight metal cellular structures via indirect 3D printing and casting In Proceedings of the International Solid Freeform Fabrication Symposium, pp. 162-176. 2012

  7. Frank, M.C., et al. A hybrid rapid pattern manufacturing system for sand castings

  8. Chua CK, Chou SM, Wong TS (1998) A study of the state-of-the-art rapid prototyping technologies. Int J Adv Manuf Technol 14(2):146–152

    Article  Google Scholar 

  9. Song JL et al (2007) Rapid prototyping manufacturing of silica sand patterns based on selective laser sintering. J Mater Process Technol 187–188:614–618

    Article  Google Scholar 

  10. M.M. Akarte and B. Ravi (2010) RP/RT route selection for casting pattern development All IndiaManufacturing Technology, Design and Research Conference: p. 8

  11. Dean Snelling, et al. 2013 The effects of 3d printed molds on metal castings. Solid Freeform Fabrication Symposium: p. 827–845

  12. Holtzer M, Górny M, Dańko R (2015) Microstructure and properties of ductile iron and compacted graphite iron castings. 1 ed. In: SpringerBriefs in Materials. Springer International Publishing XII, New York, p 158

    Google Scholar 

  13. Material data sheet for furan-direct-binding (FDB) sand molds. 2016; Available from: http://www.voxeljet.com/materials/sand/

  14. Ederer, I. and R. Hochsmann, Rapid-prototyping method and apparatus, U.S. Patent, Editor. 2005, VoXeljet Technology GmbH, Augsburg (DE): USA. p. 17

  15. Nwaogu UC, Tiedje NS (2011) Foundry coating technology: a review. Mater Sci Appl 2(08):1143–1160

    Google Scholar 

  16. Snelling, D. (2013) Mitigating gas defects in castings produced from 3D printed molds. In 117th Metalcasting Congress. Afsinc

  17. Peters F et al (2008) Effect of mould expansion on pattern allowances in sand casting of steel. Int J Cast Metal Res 20(5):275–287

    Article  Google Scholar 

Download references

Funding

JZ acknowledges the financial support provided by Walmart Foundation (project title: Optimal Plastic Injection Molding Tooling Design and Production through Advanced Additive Manufacturing); Jin Sung Precision Metal Co., Ltd., Republic of Korea (project title: Development of ceramic core for fabricating 450 mm impeller with flow thickness of 4 mm based on 3D printing technology, and its commercialization technology); and the Korea Institute of Energy Technology Evaluation and Planning (KETEP), with the financial resource from the Ministry of Trade, Industry & Energy (MOTIE), Republic of Korea (No. 20172020108530).

Author information

Authors and Affiliations

  1. Department of Mechanical and Energy Engineering, Indiana University—Purdue University Indianapolis, Indianapolis, IN, 46202, USA

    Nishant Hawaldar & Jing Zhang

Authors
  1. Nishant Hawaldar
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jing Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jing Zhang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Hawaldar, N., Zhang, J. A comparative study of fabrication of sand casting mold using additive manufacturing and conventional process. Int J Adv Manuf Technol 97, 1037–1045 (2018). https://doi.org/10.1007/s00170-018-2020-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2020-z

Keywords

Search

Navigation