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2009-Rapid_prototyping– a technology transfer approach for development of rapid tooling

Rapid prototyping–a technology transfer approach for development of rapid tooling

Dilip Sahebrao Ingole

Department of Mechanical Engineering,Prof.Ram Meghe Institute of Technology and Research,Badnera,India

Abhay Madhusudan Kuthe

Department of Mechanical Engineering,Visvesaraya National Institute of Technology,Nagpur,India

Shashank B.Thakare

Department of Mechanical Engineering,Prof.Ram Meghe Institute of Technology and Research,Badnera,India,and

Amol S.T alankar

Department of Mechanical Engineering,Gyan Ganga Institute of Technology and Sciences,Jabalpur,India

Abstract

Purpose–The purpose of this paper is to apply rapid prototyping(RP)philosophy as a technology transfer in industries to take its time and cost-effective advantages for development of rapid tooling(RT).

Design/methodology/approach–Experimentations are performed for development of RT for sand casting,investment casting and plastic moulding applications.

Findings–This paper reports the procedures developed for manufacture of production tooling using RP.A cost/benefit model is developed to justify implementation of RP as a technology transfer in industries.

Research limitations/implications–The examples are limited to parts build by fused deposition modelling RP process.However,the concepts experimented may be applied for other RP processes.

Practical implications–RP has proved to be a cost-effective and time-efficient approach for development of RT,thereby ensuring possibility for technology transfer in casting as well as plastic industries.

Originality/value–This is the pioneer attempt towards quantifying RP benefits,in view of technology transfer.This paper presents original case studies andfindings on the basis of experimentations performed in foundries.

Keywords Rapid prototyping,Machine tools,Cost-benefit analysis

Paper type Case study

1.Introduction

Despite the substantial research in CAD/CAM technology, the gap between CAD and CAM have been identified in two aspects:

1rapid creation of3D models and prototypes;and

2cost-effective production of tooling required for casting industry.

Rapid technologies(RTs)are the solutions for physical realization of products well before full-scale manufacturing (Y an and Gu,1996).Rapid manufacturing(RM),rapid tooling(RT),rapid prototyping(RP),virtual prototyping and reverse engineering are the range of technologies considered under RTs.The RP processes can be used for directly producing the casting patterns referred to as direct RT.Several researchers have explored rapid casting development using RP and RT(Chua et al.,1999;Pham and Gault,1998; Chakradeo and Kulkarni,2002;Rooks,2002;Pal et al.,2002; Rathore et al.,2002;Ingole et al.,2006).

Pattern development is the main bottleneck in terms of time and cost for manufacturing intricate castings in the foundries.T o substantially shorten the time for developing patterns,moulds and prototypes,RP is an ideal method for complex patterns making and component prototyping (Chakradeo and Kulkarni,2002;Rooks,2002).In particular,the use of RP processes has proved to be a cost-effective and time-efficient approach for producing patterns and core boxes for sand casting(Wang et al., 1999).Mueller(2005)reported that the RP patterns not only lowers cost and shortens lead times for low-volume casting jobs,but also it enables investment casting to compete with machining and weldments for very low-volume projects,even quantities of one.

There are two ways to realize the tooling using RP.Thefirst is to obtain the mould cavity and deposit a layer of metal on

The current issue and full text archive of this journal is available at http://www.wendangku.net/doc/3bf0a7e9daef5ef7ba0d3c7b.html /1355-2546.htm

Rapid Prototyping Journal

15/4(2009)280–290

q Emerald Group Publishing Limited[ISSN1355-2546] [DOI10.1108/13552540910979794]

Received:15August2008

Revised:14January2009

Accepted:12March2009 280