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TEKA Kom. Mot. Energ. Roln. OL PAN, 2011, 11, 197208APPLICATION OF THE SELECTED TECHNIQUES OF RAPID PROTOTYPING TO THE DESIGN AND MANUFACTUREOF PROTOTYPE ELEMENTS OF MACHINES AND EQUIPMENTPiotr Kowalski, Zbigniew Pczek, Robert uczekFoundry Research Institute, 73 Zakopiaska Str., 30-418 Cracow, PolandSummary. By using rapid prototyping techniques, prototype parts, components or finished products can be quickly manufactured. The elements of a new device can serve as an example of the practical use of this solu- tion. The result of the studies was a short series of prototype parts. Due to the functions performed by these elements, they were made from specially selected plastics characterised by mechanical properties allowing for the initial testing of prototype. The design of parts was based on the three-dimensional computer models. Owing to the availability of the FDM Titan device, in a short time real patterns were obtained. They were used to make silicone dies which, in turn, were used for casting a short series of prototypes from plastics. The components obtained in this way were subjected to tests to check their functionality. A series of test castings was also made.Keywords: rapid prototyping, designing of new products, metalcasting, plastics.INTRODUCTIONIn a modern market economy and competition, quick manufacture of prototypes of the high- est quality becomes a must. To satisfy high requirements of customers and shorten the lead times, manufacturers are forced to use innovative methods of production, based on the computer-aided design and the latest achievements of rapid prototyping and tooling performance. For several years these issues have been the subject of research conducted by the Centre for Design and Prototyping at the Foundry Research Institute in Cracow. Until now, numerous application works for different customers have simultaneously been implemented. 711The last decade has seen a tremendous progress in the application of computer-aided product manufacturing. The abbreviations like CAD (Computer Aided Design), CAM (Computer Aided Manufacturing), CAE (Computer Aided Engineering) are now generally known, and the opportuni- ties offered by them are widely used by engineers in various industries 26, 13.In particular, significant progress can be seen in the rapid manufacture of new products, which is usually preceded by the need of making prototypes. This is particularly true in the automotive industry, engineering, defence, aviation and more recently in telecommunications. Metalcasting, be- ing major supplier of components for a wide range of customers, including also the aforementioned sectors of industry, must use and uses the possibilities offered by the advanced application of CAD/ CAM / CAE systems.APPLICATION OF THE SELECTED TECHNIQUES OF RAPID PROTOTYPING209The most notable progress has been observed in the last few years in the field of rapid pro- totyping (RPS) and rapid tooling (RT). Rapid prototyping technique came into use in 1987, when the 3D Systems Company launched the first device for the manufacture of foundry patterns from liquid synthetic resin, the successive layers of which were hardened with a beam of ultraviolet laser light. In this way the technique known as stereolithography RPS was born.Considering the benefits offered by rapid prototyping, the subsequent years witnessed its outstanding development. New techniques and stands for the manufacture of patterns were devel- oped. Currently, rapid prototyping is seen as an obvious step in the preparation of a new product.According to data for the year 2008 1, the area of application of patterns/parts made by RP and RT is as follows: 13.7% utility models for presentation, 10.0% parts of complex models, 15.3% visualisation (aid) in engineering studies, 3.4% models as a part of tooling, 6.5% patterns for foundry, 12.5% models to make prototype tools, 5.3% models to aid the implementation of various projects, 4.6% other applications.The best-known techniques of RP and RT with their respective applications have been broadly described in information materials published by different companies offering equipment for practical implementation of these techniques, and also in numerous publications and online data. Considering the above, the presentation of these techniques has been omitted in this paper. 1,1222The general principle of RP and RT is essentially the same and consists in reproduction and successive application of very thin layers of the pattern. The shape of the formed piece is written in advance in computer memory, using a graphical editor operating in a triaxial (3D) system.Depending on the used techniques, the pattern is usually built from liquid synthetic resin, paper, powders of different materials, wax. High precision of the manufactured patterns ensures the application of advanced optics (including laser technology) for curing the individual layers or cutting them out.Patterns are made on specially equipped work stands, typical for a given technique. The size of the manufactured patterns is limited by the dimensions of a worktable. If larger patterns are to be made, it is sometimes possible to apply techniques which enable joining various elements reproduc- ing parts of a workpiece. Different RP techniques have strictly determined the scope of application and precision (the accuracy of reproducing pattern shape). They differ quite obviously in the cost of the equipment and materials used.The application of RP techniques caused revolutionary changes in the way the new production has been prepared and new equipment designed.Currently, in the world market, a strong competition is going on within a large group of the well-known companies that offer all the available techniques of rapid prototyping, supplying the equipment, materials, maintenance and services.The choice of an RP technique is usually determined by a number of factors, among which the following ones should be mentioned here: pattern dimensions, pattern application, pattern dimensional accuracy, pattern price.All these factors were analysed at the Foundry Research Institute before a decision was taken about the purchase of various stands for rapid prototyping, mainly for the needs of foundry industry,but not only. When the decision was taken to establish a Centre for Design and Prototyping at the Foundry Research Institute, the above criteria were considered, the most useful techniques of RPS were selected, and the necessary equipment was purchased.As a result of these actions, the Centre uses the following devices and the following tech- niques: LOM Solidscape FDM 3DprintingPURPOSE AND SCOPE OF STUDYThe aim of this study was to examine the possibility of using one of the techniques of rapid prototyping (FDM - Fused Deposition Modelling) in the manufacture of parts of a prototype device. The scope of the study included design and manufacture of prototype components.MATERIALS AND METHODSIn the studies, the FDM Titan device from Stratasys (Figure 1) was used. It enabled making patterns from plastics. The FDM Titan is a modern facility, used to create functional and visual patterns from plastics. The pattern-building process involves depositing successive layers of mate- rial fed to the worktable in semi-solid state. In this technique, the pattern material are various types of plastics, which in the form of a wire wound on a spool are supplied from trays to a head mov- ing in the X-Y axes. In the heating elements of a thermal head unit, two nozzles are mounted: the nozzle feeding pattern material and the nozzle feeding support material. In these nozzles, the wire fed from a tray is preheated until it reaches a semi-solid state. Then the melted pattern material and support material are squeezed by nozzles onto a special base board placed on the worktable moving vertically in the Z-axis to form the first layer of a built pattern, according to horizontal cross-sections generated by an Insight programme cooperating with the FDM Titan device. With modelling of a specific layer of the item completed, the worktable is lowered by a preset thickness, and the solidified shell is acting as a support for further applied layers. The thickness of the material filament fed during pattern building depends on the nozzle type and on the type of pattern material used and can be: 0.127 mm, 0.178 mm, 0.254 mm and 0.33 mm. The worktable size is limited to 406 x 355 x 406 mm, but the built patterns have no size restrictions, since individual components of a complex structure can be combined by gluing.Fig. 1. FDM Titan device made by StratasysDespite the commercial availability of many similar printers using FDM technique, the FDM Titan device is the only device in the country which enables modelling of plastics. Patterns are made from several materials like: ABS (acryl-nitril-butadienestyrene), PC (polycarbonate), PC-ISO (for medical applications), PPSF/PPSU (polyphenylsulphon).The available pattern plastics can be divided into two groups, depending on the type of the used support material: pattern materials using broken off support (PC, PC-ISO, PPSF), pattern materials using support soluble in appropriate basic solutions (ABS and PC-ABS).The proposed pattern materials are supplied in white colour, while in the case of ABS seven- colour palette is available. Additionally, it is possible to build patterns from two types of transparent materials: ABSi (three colours of transparency) and PC-ISO. As already mentioned, ABS is the material from which both colour and transparent patterns can be made, but apart from visual effects, owing to the use of soluble support, an additional advantage of this material is the ability to make complex patterns with a series of internal channels.The second material using soluble support is the material of a trade name PC-ABS, combin- ing the properties of ABS and PC. Patterns made from ABS and PC are characterised by relatively high strength and low shrinkage. Their basic drawback is the loss of shape at temperatures as low as 100C.The material offering the highest strength and temperature of plastic deformation is PPSF. At temperatures up to about 190C, patterns made from this material do not undergo deformation, are characterised by relatively good thermal and chemical resistance, as well as environmental resis- tance to aggressive liquids such as unleaded petrol, engine oil, coolant and washer fluid.Items made from these materials, apart from visual - advertising value can serve as useful parts, (otherwise called Real PartsTM), as patterns for castings made in ceramic moulds by the lost foamprocess or by direct moulding in traditional processes, or as master-patterns to make silicone dies for wax patterns. The ready prototype patterns can be subjected to finishing treatment by e.g. grinding or drilling; finally, to obtain the required outer surface quality, they are painted or chrome-plated.RESULTS OF INVESTIGATIONSStudies discussed in this article formed part of Development Project 0R00004005 executed in 2010 by the Centre for Design and Prototyping at the Foundry Research Institute in Cracow. During tests, prototype items varying in size and complexity were made. In future they will be produced by the gravity and die casting processes.At the present stage of research, prototype castings were made by the lost wax process and vacuum casting in plaster moulds. The necessary drawing documentation of those elements was prepared in a 3D system using a SolidEdge graphical editor.The ready drawings helped to prepare the equipment for operation and making FDM models. Prior to casting manufacture, the following technology steps were developed: filling mould cavity, casting solidification and cooling. The technology was checked using a specialised MAGMAsoft software. Below a specification of the examined items is given.Item No. 1Name : WheelCast material : AK7 aluminium alloy Weight : 0,1 kgIn future this item will be made by die casting process.The following elements were successively made: FDM model, silicone resin die and wax patterns.Castings were made by the lost wax process. Items were cast in ceramic molochite moulds.Altogether 4 sets with 6 castings in each set were made.The following checking tests were performed on castings: structure examinations; hardness measurements; dimensional accuracy : RPS model, die, wax pattern, casting.Item No. 2Name : CrossCast material : AK7 aluminium alloy Weight : 0,10 kg (10 g)In future this item will be made by die casting process.The following elements were successively made: FDM model, silicone resin die and wax patterns.Castings were made by the lost wax process. Items were cast in ceramic molochite moulds.Altogether 4 sets with 6 castings in each set were made. The following checking tests were performed on castings: structure examinations; hardness measurements; dimensional accuracy : RPS model, die, wax pattern, casting.Ceramic moulds were made on an automatic CYKLON device from MK Technology GmbH in Germany.Photographs below present successive operations performed at this stand: pattern set ready for application of the first ceramic coating application of ceramic coating supporting mould with loose ceramic material drying of ceramic coatingFig. 2. Pattern set ready to make a ceramic mouldFig. 3. Application of ceramic coatingFig. 4. Mould supported with loose ceramic materialFig. 5. Drying of applied ceramic coatingItem No. 3Name : ElbowCast material : AK7 aluminium alloy Weight : 0,398 kgIn future this item will be made by gravity die casting process with sand core.The following elements were successively made: FDM model, silicone resin die and wax patterns.Castings were made by the lost wax process. Items were cast in plaster moulds.The following checking tests were performed on castings: structure examinations; hardness measurements; dimensional accuracy : RPS model, die, wax pattern, casting.Item No. 4Name: SleeveCast material : AK7 aluminium alloy Weight : 0,621 kgIn future this item will be made by gravity die casting process with sand core.The following elements were successively made: FDM model, silicone resin die and wax patterns.Castings were made by the lost wax process. Items were cast in plaster moulds.The following checking tests were performed on castings: structure examinations; hardness measurements; dimensional accuracy : RPS model, die, wax pattern, casting.The structure examinations and hardness measurements taken on the four prototype castings confirmed that the technical parameters corresponding to standard requirements for AK7 alloy had been obtained.The dimensional accuracy was checked using an optical 3D scanner ATOS III. It allows for the scanning (measuring the coordinates of points) of objects with overall dimensions from several millimetres up to several metres. ATOS operating principle is that of triangulation. Two cameras observe the run of fringes in the examined item and for each camera pixel the coordinate point is calculated with high precision. The maximum number of measuring points in a single shot is 4 000 000. The time for one shot is 2 seconds. The measuring fields are 150x150 and 500x500 mm.The use of special software enables a complete analysis of the measurement (dimensioning of the item, compatibility with CAD data, coloured map of deviations, inspection sections, etc.) Quality control is one of the areas where optical 3D scanner ATOS III is used. It enables comparing the examined object with CAD model design, or comparing two identical objects. It also enables dimensioning of arbitrary cross-sections and geometrical features. The use of automatic rotary tables enables total quality control and analysis of shrinkage,ATOS III 3D is used in tool shops as a means for performance control, verification of process- ing, and tool reproduction. It also enables comparing the mould with pattern, digital recording and documentation. The 3D optical scanner using structured light emits onto the measured object a set of white light fringes characterised by a specific density of packing. The packing density of fringes enables specifying the amount of data received. With more fringes, more of data are received. These fringes are subjected to unequal distortion, and the image of the illuminated object is recorded by objective lenses mounted in the scanner head. As a result of the measurement carried out by this technique, a set of structured light fringes, lying on the surface of the object and at the time of illumination visible to both lenses, is obtained. The resulting sets of fringes are superimposed by means of reference points. So, prior to scanning, reference points are applied on patterns.The image formed as a result of scanning is point cloud, and therefore the obtained model is subjected to polygonisation. This means that the point cloud is converted to a network of non- overlapping triangles. The created polygonal network is subjected to further processing, and the task of this processing is to remove reference points, fill surface discontinuities, and smooth them whenever possible. Thus prepared network of triangles is a model of the real object.ATOS III programme for processing of scanned models allows reproduction of the model surface. It also allows fitting of models to each other.The studies of dimensional accuracy made with the use of the described scanner fully con- firmed the dimensional compatibility of models and castings made within the range of values ex- pected for the ready cast elements.CONCLUSIONSThe studies fully confirmed the applicability of FDM technique in creation of models used for the manufacture of prototype castings.The possibility of making prototype castings using equipment available at the Centre for Design and Prototyping has been confirmed. The prototype castings can be used in verification of the design assumptions, while their lot production by selected casting technology can be undertaken as the next step.Considering high surface quality and dimensional accuracy, models made by FDM techniques can successfully serve as prototype parts made from plastics.REFERENCESDevelopment Project 0R00004005, Foundry Research Institute, Cracow 2010 WOHLERS ASSOCIATES Wohlers Report 2009, , Inc. Colorado, USAOCZO K.E.: Rosnce znaczenie Rapid Manufacturing w przyrostowym ksztatowaniu wyrobw.Mechanik (2008)4, 256.OCZO K.E.: Zastosowanie techniki Rapid Tooling do kontroli jakoci wytwarzanych czci samo- chodowych. Mechanik (2008)12, 1022-1028.OCZO K.E.:Rozwj ksztatowania przyrostowego wyrobw. Mechanik (2007)2,65OCZO K.E., Rapid Prototyping - znaczenie, charakterystyka metod i moliwoci, Mechanik 1997, 70 nr 10 s.441 452CHLEBUS E.: Innowacyjne technologie Rapid Prototyping Rapid Tooling w rozwoju produktu. Oficyna Wydawnicza Politechniki Wrocawskiej. Wrocaw 2003, s.37-42,47-57,106-140,152- 158PCZEK Z., KARWISKI A., KROKOSZ J., PRZYBYLSKI J., PYSZ S.: Zastosowanie technikLOM do wykonywania odleww, moliwoci, szanse, problemy, wyd. Instytut Odlewnictwa Krakw, Krakw, 2003KROKOSZ J., MODNICKI S., GIL A., KARWISKI A., PABI R., WIKLAK R.: Ocenamoliwoci wykorzystania technik szybkiego prototypowania w odlewnictwie oraz opracow- anie zaoe i wykonanie serii modeli i odleww artystycznych, Odlewnictwo wspczesne Polska i wiat 2010, nr 1, str.3-13PYSZ S., Karwiski A., Czekaj E.: An Analysis and Comparison of Properties of Al-Si Alloy Au- tomotive Castings Made by Rapid Prototyping and Standard Lot Production. TEKA Komisji Motoryzacji i Energetyki Rolnictwa OL PAN, Tom IX, Lublin 2009, pp. 250 258.Pirowski Z., Gociaski M.: Constraction and Technology of Production of Casted Shares for Rotat- ing and Field Ploughs. TEKA Komisji Motoryzacji i Energetyki Rolnictwa OL PAN, Tom IX, Lublin 2009, pp. 231 239.Development Project 0R00004005, Foundry Research Institute, Cracow 2010PLICHTA J., PLICHTA S.: Techniki komputerowe w inynierii produkcji. Wydawnictwo Uczelniane Politechniki Koszaliskiej, KoszalinRUSZAJ A.: Niekonwencjonalne metody wytwarzania elementw maszyn i narzdzi. Wydawca IOS w Krakowie. Krakw 1999,s.288,299BUBICZ M.: Raport: Szybkie prototypowanie cz. I przegld dostpnych rozwiza. Maszyny, materiay, zastosowania. / Projektowanie i Konstrukcje Inynierskie 6(09) czerwiec, 2008, p. 14 - 21.BUBICZ M.: Cyfrowe czy jednak fizyczne? Prototypowanie wyzwanie XXI wieku, Konstrukcje inynierskie 2007, nr 1CHOJNOWSKA L.: Model wirtualny wsparty wydrukiem 3D. Desing News w Mechanice i Elek- tronice, 2008, nr 03PATEK P., Kret M.: Techniki druku 3D przykady zastosowa metody FDM, warstwowego osad- zania topionego materiau. Seminarium techniki szybkiego prototypowania w cyklu ycia produktu. Mechanik” 2008, nr12.DYBAA B.: Technologie szybkiego prototypowania i wytwarzania, W: Raport. Rapid Prototyping & Reverse Engineering”, 2010LEWANDOWSKI J.L.: Postp w zakresie szybkiego prototypowania, Przegld Odlewnictwa 3/2001 str. 116-117CHUA C.K., LEONG K.F., LIM C.S.: Rapid Prototyping. Principles and Applications, World Sci- entific, Singapoore 2004.GUSTAFSON R.: Rapid Prototyping: a tool for casting design and verification, Mod. Casting 1999 Vol.89 nr 3 s.44-47WUENSCHE R.: Rapid Prototyping bei der Herstellung von Gussteilen, Giesserei 2004 Jg.91 H.4 s.44-46ZASTOSOWANIE WYBRANYCH TECHNIK RAPID PROTOTYPING DO WYKONYWANIA PROTOTYPOWYCH ELEMENTW KONSTRUKCJI MASZYN I URZADZE.Streszczenie. Dziki zastosowaniu technik Rapid Prototyping istnieje moliwo szybkiego wytworzenia pro- totypowych czci, podzespow lub gotowych produktw. Przykadem zastosowania takiego rozwizania s elementy nowego urzdzenia. Efektem prowadzonych prac byo uzyskanie krtkiej serii prototypowych czci. Ze wzgldu na speniane funkcje, do wykonania ich zastao dobrane odpowiednie tworzywo sztuczne o wa- ciwociach mechanicznych pozwalajcych na wstpne testowanie prototypu. Podstaw do wykonania detali byy trjwymiarowe modele komputerowe. Dziki wykorzystaniu urzdzenia FDM Titan w krtkim czasie uzyskano modele rzeczywiste, nastpnie na ich podstawie zostay wykonane matryce silikonowe, ktre z kolei posuyy do odlania krtkiej serii prototypw z tworzywa sztucznego. Tak uzyskane elementy zostay przeka- zane do testw w celu sprawdzenia ich funkcjonalnoci. Wykonano rwnie seri odleww z moliwoci ich wykorzystania do testowania.Sowa kluczowe: szybkie prototypowanie, projektowanie nowych wyrobw, odlewnictwo, tworzywa sztuczne.特卡库姆莫特。能量。罗恩- OL PAN，2011, 11, 197 - 208快速成型技术在设计制造中的应用机器和设备的原型元素Piotr Kowalski、兹比格涅夫P捷克、罗伯特乌塞克铸造研究所，73 ZaopiaSka STR，Cracow，波兰概要通过使用快速原型技术，可以快速制造原型零件、部件或成品。新装置的元件可以作为该解决方案的实际使用的一个例子。研究的结果是一系列短的原型零件。由于这些元件所执行的功能，它们由特殊选择的塑料制成，其特征在于机械性能允许原型的初始测试。零件的设计是基于三维计算机模型的。由于FDM泰坦设备的可用性，在短时间内获得真实图案。它们被用来制造硅树脂模具，而这又是 用来从塑料铸造一系列短原型。以这种方式获得的组分经受测试以检查它们的功能性。还进行了一系列的试验铸件。关键词：快速成型，新产品设计，金属铸造，塑料。说明在现代市场经济和竞争中，快速制造高质量的样板成为必然。为了满足客户的高要求和缩短交货时间，制造商被迫使用创新的生产方法，基于计算机辅助设计和最新的快速原 型和模具性能的成就。几年来，这些问题一直是Cracow铸造研究所设计和原型中心进行的 研究课题。直到现在，许多不同客户的应用工作也同时被实施。 7比11 近十年来，计算机辅助产品制造的应用取得了巨大的进步。缩略语如CAD（计算机辅助设计）、CAM（计算机辅助制造）、CAE（计算机辅助工程）现在已经普遍知道，它们 所提供的机会被各个行业的工程师广泛使用26, 13。特别是，在新产品的快速制造中可以看到显著的进步，这通常是在需要制造原型之前。这在汽车工业、工程、国防、航空以及最近的电信领域尤为如此。Mel铸是一个广泛的客户的 主要供应商，包括前述行业部门，必须使用和使用先进的CAD应用提供的可能性。/CAM/CAE系统。9快速成型技术的应用在过去的几年中，在快速成型（RPS）和快速模具（RT）领域中观察到了最显著的进步。1987年初，当3D系统公司推出了第一种由液态合成树脂制造铸造图案的装置时，快速成型技术被连续地用一束紫外激光束硬化。以这种方式，被称为立体光刻技术的技术诞生了。考虑到快速成型所带来的好处，随后几年见证了它的杰出发展。开发了新的技术和代表图案的制造。目前，快速成型被看作是新产品制备过程中的一个明显步骤。根据2008（1）年的数据，RP和RT制作的图案/零件的面积如下： 13.7%实用新型-用于演示， 复杂模型的10%个部分， 工程研究中的15.3%种可视化（AID） 3.4%个模型作为工具的一部分， 铸造6.5%种模式， 12.5%种制作原型工具的模型， 有助于实施各种项目的5.3%种模式， 其他4.6%个应用程序。RP和RT与它们各自的应用最为著名的技术已经在不同公司出版的信息材料中广泛地描述，这些设备提供了这些技术的实际实现的设备，并且在许多出版物和在线数据中。鉴 于此，本文省略了这些技术的介绍。1,12- 22 RP和RT的一般原理本质上是相同的，包括在非常薄的图层的再现和连续应用中。使用在三轴（3D）系统中操作的图形编辑器，在计算机存储器中预先形成成形件的形状。根据使用的技术，图案通常是由液体合成树脂，纸张，不同材料的粉末，蜡。高精度 的制造模式确保了先进的光学（包括激光技术）的应用，以固化个别层或切割出来。图案是在特制的工作台上制作的，典型地用于给定的技术。所制造的图案的尺寸受工作台尺寸的限制。如果要制造更大的图案，有时可以应用能够接合各种元件再现工件的部 件的技术。不同的RP技术严格地确定了应用范围和精度（再现图案形状的精度）。它们在使用的设备和材料的成本上差别很大。RP技术的应用给新产品的制备和新设备的设计带来了革命性的变化。目前，在世界市场，一个强大的竞争正在进行的一大组的知名公司，提供所有可用的技术，快速原型，提供设备，材料，维修和服务。RP技术的选择通常是由若干因素决定的，其中这里应提到以下几个因素： 图案尺寸， 模式应用 图形尺寸精度， 模式价格。所有这些因素在铸造研究所进行了分析，然后决定购买各种快速原型的支架，主要是为了铸造行业的需要。但不仅如此。当决定在铸造研究所建立一个设计和原型中心时，考虑上述标准，选择最有 用的RPS技术，并购买必要的设备。作为这些行动的结果，该中心使用以下设备和以下技术： 洛姆 立体景观 频分复用 3D印目的与研究范围本研究的目的是检查使用快速原型技术（FDM熔融沉积建模）的一种原型器件的制造 中的一种可能性。研究的范围包括原型部件的设计和制造。材料与方法在研究中，使用了来自StalasyS的FDM泰坦装置（图1）。它能用塑料制作图案。FDM TITAN是一个现代化的设施，用来创造功能和视觉模式从塑料。该模式建立过程涉及沉积连 续层的材料供给到工作台在半固态。在该技术中，图案材料是各种类型的塑料，其以缠绕 在阀芯上的线的形式从托盘供应到在X-Y轴中移动的头部。在热头单元的加热元件中，安装有两个喷嘴：喷嘴进给模式材料和喷嘴进给支撑材料。在这些喷嘴中，从托盘馈送的电 线被预热，直到它达到半固态。然后，将熔融的图案材料和支撑材料通过喷嘴挤压到放置 在工作台上的Z轴上垂直移动的特殊基板上，以根据与FDM TITAN设备合作的洞察方案产生的水平横截面形成第一层的内置图案。随着完成的项目的特定层的建模，工作台被降低了 预设厚度，并且固化的外壳作为进一步施加的层的支撑。在图案构建期间馈送的材料丝的 厚度取决于喷嘴类型和所使用的图案材料的类型，并且可以是： 0.127毫米、0.178毫米、0.254毫米和0.33毫米。工作台尺寸限制在406355406 mm，但是所构建的图案没有尺寸限制，因为可以通过胶合来组合复杂结构的各个部件。图1。StalasyS公司制造的FDM泰坦装置尽管使用FDM技术的许多类似打印机的商业可用性，FDM泰坦设备是在该国唯一的设备， 使塑料建模。图案是由几种材料制成的： ABS（丙烯腈基丁二烯） PC（聚碳酸酯），PC-ISO（医学应用）， PPSF/PPSU（聚苯硫醚）。可用的图案塑料可分为两组，这取决于所使用的支撑材料的类型： 使用断开支撑的图案材料（PC、PC-ISO、PPSF）； 使用可溶解于适当碱性溶液（ABS和PC-ABS）的载体的图案材料。所提出的图案材料是白色的，而在ABS SEVCONCOLL的情况下，调色板是可用的。此外， 有可能从两种类型的透明材料：ABSi（三种颜色的透明度）和PC-ISO构建图案。正如已经提 到的，ABS是既可制成彩色图案又可制成透明图案的材料，但除了视觉效果外，由于使用可溶性载体，这种材料的另一个优点是能够用一系列内部通道制造复杂图案。使用可溶性载体的第二种材料是商品名PC-ABS的材料，结合ABS和PC的特性。ABS和PC 制成的图案的特征在于相对高的强度和低的收缩率。它们的基本缺点是在温度低到100时失去形状。提供最高强度和塑性变形温度的材料是PPSF。在高达约190的温度下，由这种材料制成的图案不发生变形，其特征在于具有相对良好的耐热性和耐化学性，以及耐腐蚀性液 体如无铅汽油、发动机油、冷却剂和洗涤液的耐环境性。除了视觉广告值之外，由这些材料制成的物品可以作为有用的部件，（称为实心部件Tm值），作为消失模在陶瓷模具中制造的铸件的图案。工艺或直接成型在传统工艺，或作为主要模式，使硅酮模具蜡模式。准备好的原型图案可 以通过磨削或钻孔进行精加工；最后，为了获得所需的外表面质量，它们被涂漆或镀铬。调查结果本文所讨论的研究是由Cracow铸造研究所设计和原型设计中心在2010执行的开发项目09000400 5的一部分。在测试过程中，原型项目的大小和复杂程度不同。未来，它们将由重力铸造和压铸工艺生产。在现阶段的研究中，采用消失模法和真空铸造法在石膏模具上制作原型铸件。使用SOLIDIDEGE图形编辑器在3D系统中准备这些元素的必要绘图文档。准备好的图纸有助于准备操作和制造FDM模型的设备。在铸造生产之前，开发了充型腔、铸造凝固和冷却等工艺步骤。使用专门的MAGMASOFT软件对该技术进行了检查。下 面给出了检查项目的规范。第1项名称：车轮铸造材料：AK7铝合金重量：0，1公斤今后该项目将采用压铸工艺进行。先后制作了FDM模型、有机硅树脂模具和蜡模。 铸件是用失蜡法制造的。项目是铸造陶瓷莫洛石模具。共制作4套，每组6件铸件。对铸件进行以下检查试验： 结构检查； 硬度测量； 尺寸精度：RPS模型、模具、蜡模、铸件。第2项姓名：十字架 铸造材料：AK7铝 合金重量：0，10公斤（10克）今后该项目将采用压铸工艺进行。先后制作了FDM模型、有机硅树脂模具和蜡模。 铸件是用失蜡法制造的。项目是铸造陶瓷莫洛石模具。共制作4套，每组6件铸件。对铸件进行以下检查试验： 结构检查； 硬度测量； 尺寸精度：RPS模型、模具、蜡模、铸件。陶瓷模具是在德国的MK技术有限公司的自动Cykon设备上制造的。 以下照片在本站进行连续操作： 适用于第一陶瓷涂层的图案组 陶瓷涂层的应用 松动陶瓷支撑模 陶瓷涂层干燥图2。图案集准备制作陶瓷模具图3。陶瓷涂层的应用图4。松散陶瓷材料支撑的模具图5。陶瓷涂层的干燥第3项姓名：Elbow铸造材料：AK7铝合金重量：0398公斤今后该项目将采用砂芯重力铸造工艺进行。先后制作了FDM模型、有机硅树脂模具和蜡模。 铸件是用失蜡法制造的。用石膏模浇铸物品。对铸件进行以下检查试验： 结构检查； 硬度测量； 尺寸精度：RPS模型、模具、蜡模、铸件。第4项姓名：袖子铸造材料：AK7铝合金重量：0621公斤今后该项目将采用砂芯重力铸造工艺进行。先后制作了FDM模型、有机硅树脂模具和蜡模。 铸件是用失蜡法制造的。用石膏模浇铸物品。对铸件进行以下检查试验： 结构检查； 硬度测量； 尺寸精度：RPS模型、模具、蜡模、铸件。对四个原型铸件进行了结构检验和硬度测定，得到了与AK7合金标准要求相符合的工 艺参数。使用光学3D扫描仪ATOS检查尺寸精度。它允许扫描（测量点的坐标），其总尺寸从 几毫米到几米。ATOS的工作原理是三角剖分。两个摄像机观察被检查项目中的条纹的运行， 并且对于每个摄像机像素，坐标点以高精度计算。单点测量点的最大数目是4000000。一次射门的时间是2秒。测量范围为150150和500500毫米。使用特殊的软件可以完成对测量的完整分析