ISSN: 2277-3754

International Journal of Engineering and Innovative Technology (IJEIT)

Volume 1, Issue 4, April 2012

Development of Complex Patterns: Scope and

Benefits of Rapid Prototyping in Foundries
Rajashekar Patil, S. Mohan Kumar, E. Abhilash
technology (fused deposition modeling) to eliminate the
Abstract— The quality through frugal engineering concepts material wastage in pattern production, reduce the cost and
has gained prime importance to the foundries around the world. lead-time in the production of accurate complex castings of
Although simulation packages have been used as a tool to
an acceptable surface quality. In this concern, the discussion
achieve quality and productivity, the use of Rapid Prototyping
(RP) is not yet fully practiced in foundries in this concern. This is made on the development of impeller casting using
paper provides a detailed study of the fabrication of a complex aluminum alloy, both by conventional as well as RP
master pattern (impeller casting) using rapid prototyping processing route.
technique besides presenting its scope and benefits compared to II. DESIGN AND FABRICATION OF COMPLEX MASTER
the current practices. The main objective of this work is to PATTERNS
enlighten the foundry engineers to make use of rapid prototyping The cost of any casting increases in direct proportion to the
technology (fused deposition modeling) to eliminate the material
wastage in pattern production, reduce the cost and lead-time in
preciseness of its dimensional tolerance requirements and
the production of accurate complex castings of an acceptable also the surface finish. Approximate values of surface
surface quality. roughness (generally specified by ISO number, N1 to N12)
and tolerance on dimensions typically obtained with different
Index Terms—Complex Pattern, Rapid Prototyping, Fused manufacturing processes is shown in Figure 1. Casting
Deposition Modeling, Sand Casting. process, especially the investment casting process is one of
the near-net shape manufacturing processes, designed to
I. INTRODUCTION minimize the cost of producing close tolerance parts.
The competitive market has always given a prime Maintaining close dimensional tolerance in a casting is
importance to minimize the production cost, lead time and affected by many factors. Most of these factors can be
deliver good quality products at an affordable price. Casting controlled in the foundry, although minor variations can
is generally justifiable only when it is produced in large occur among each batch of productions due to uncontrollable
volumes due to the high cost of tooling for pattern/die factors.
making. Rapid Prototyping (RP) has been introduced to the
industries to facilitate reverse engineering and to produce
castings even when the order quantity is as low as unity. RP
has simplified pattern making which was hitherto a skilled
job and depended on artisans. Over the years, there have been
many developments in RP technologies to favor casting
process [1,2].Patterns made from Laminated Object
Manufacturing (LOM), Fused Deposition Modeling (FDM)
and Selective Laser Sintering (SLS) are strong enough to
replace the traditional wooden patterns [3]. Recently, SLS
processing is used to manufacture silica sand patterns which
may be used as sand cores too [4]. Today, foundry engineers
are much aware of the benefits of using computer aided
design and simulation packages to evaluate defects and
ensure the quality and productivity. However, the removal of Fig.1 Approximate values of surface roughness and
defects generated from master patterns such as dimensional tolerance on dimensions typically obtained with different
inaccuracy, surface quality, parting line mismatches etc. manufacturing processes [5].
have remained as a few challenges to metal casting The consistency of casting dimensions depends on the
industries. Design and fabrication of master pattern is an casting process used and the degree of process control
important pre-casting activity in casting process planning. achieved in the foundry. The system of dimensional
Though there are several advantages of using RP in the tolerances which is applicable to the dimensions of cast
production of master patterns, the use of RP is not yet fully metals and their alloys produced by sand molding, gravity die
practiced in foundries. Hence, the main objective of this work casting, low pressure die casting, high pressure die casting
is to enlighten the foundry engineers to make use of RP and investment casting is well documented in the

68
 ISSN: 2277-3754
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 1, Issue 4, April 2012
international standard ISO 8062–1994. The equivalent shows the properties of ABS-M30 and Teak wood used in the
British Standard BS6615:1996 and German Standards DIN present study. Patterns made of ABS are dense, rigid, can
1680/DIN1688 can also be referred for more details. The serve at higher temperature and has lower shrinkage
tolerance capability of the value added castings is controlled compared to that of Teak patterns.
by six main parameters [6]. These parameters according to Table 1: Properties of ABS-M30 and Teak wood
their preference are as follows: Properties ABS-M30 Teak
1. Molding process. Ultimate tensile strength 40 wood
95 - 155
2. Casting weight and longest dimension. (MPa)Compressive strength 42 48 - 91
3. Mould degrees of freedom. (MPa)Coef. of thermal 10 x 10-5 ---
4. Draft on mold, patterns and cores expn.(m/m o
C)
Thermal conductivity 0.2 0.19 -
5. Patternmaker’s contraction. o
(W/m Poisson’s
C) ratio 0.35 0.38
0.42
6. Cleaning and heat treating.
Based on the casting processes, the engineer should take Operating Temperature 60 30
o
care of additional parameters too. For example, in the case of ( C)
Density (kg/m3) 1024 630-720
investment casting process, the factors that affect casting Shrinkage (%) 0.1 0.6 - 0.6
tolerance are: (i) wax or plastic temperature (ii) firing Rapid prototyping is an automatic production of physical
temperature (iii) die temperature (iv) shell composition (v) objects using additive manufacturing technology in which
pressure of injection (vi) rate of cooling. The dimensional or the model is built layer by layer. RP takes virtual designs
shape variations caused by these factors can be addressed by from Computer Aided Design (CAD) or animation modeling
[7]: software, transforms them into thin, virtual, horizontal
 Linear tolerance which is normally applied to the cross-sections (generally in STL file format standardized by
features such as length, concentricity, fillet radii, holes, rapid prototyping industries) and then creates successive
flatness, straightness, corner radii, and curved holes. layers until the model is completed. In this study fused
 Geometric tolerance which is normally applied to the deposition modeling (FDM) is used to fabricate the complex
features such as profiles & true positioning, parallelism, master pattern. A strategic approach to achieve complex
contours, radii, roundness, perpendicularity, tapered holes, master pattern using FDM defines the specifications, plans,
and cam profiles. parameters, activities, processes and constraints. Compared
Most of the above features are explained in US military to other RP technologies such as 3D print, SLS, SLA and
standard (MIL –STD-8); however, the method of measuring Polyjet, FDM requires 6 slices of 0.178 mm to complete 1
these features can be specified by the casting purchaser. As mm thickness of the parts. Figure 2 shows a conventionally
explained, the accurate and sound castings of specified made (wooden) pattern and the pattern (ABS) fabricated
tolerance and surface finish depend on the quality of complex through RP technology (fused deposition modeling).
master pattern used in the production process. Hence, to
manufacture different grades of castings, the specified
tolerance and surface roughness grades should be achieved
accurately on the shape and geometric features of master
patterns. Generally in the foundries, the master patterns are
made using plywood, wood (Teak, Neem, Mango etc.) and
hard boards. These patterns have many limitations such as
difficulty in fabrication to achieve the exact shapes, may
require assembly of parts, are susceptible to absorption of
moisture, fungus attack, shrinkage and may require special
coating to increase the shelf life. To overcome these
difficulties, patterns made of light alloys are also used.
However, the cost, the size limitation and the easiness in
molding process are some of the limitations of metal/alloy
patterns. Recently, all these limitations are surmounted by
the introduction of polymer (thermoplastics and
photopolymers) patterns such as ABS
(Acrylonitrile-Butadiene-Styrene), PC (polycarbonate), Fig. 2 Master Pattern of Impeller Casting (a) wooden
ULTEM, PPS (Polyphenylsulfone) etc. which can be easily material (b) ABS material.
fabricated by RP machines. The usage of polymer/plastic In the current study, STRATASYS FORTUS 400mc RP
patterns have several advantages such as enhanced pattern machine was used to fabricate pattern of impeller casting.
life in product cycle, great dimensional accuracy, reduction The general methodology of making this ABS pattern
in inspection and rework and also the reusability. Table 1 involves following steps:-

69
 ISSN: 2277-3754
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 1, Issue 4, April 2012
1. Creation of CAD models of all components reduction in production cost per ABS master pattern is
2. Conversion of CAD models to STL format achieved. There are several advantages of using RP
3. Slicing of STL file into thin cross-sectional layers technology in foundries. Compared to conventional method
4. Layer by layer construction of the models and CNC machining process, RP technology is fast accurate
5. Cleaning and finishing of the RP models and manufactures the pattern without any material wastage.
The CAD models made in Solid Edge software is Since RP technology integrates numerical control, it does not
optimally (to approximate exact surfaces) converted to STL require any special tools, jigs and fixtures and secondary
format (which represents a 3D surface to an assembly of operation to build the master patterns. Since the technology
planar triangles). The individual model in STL format is is highly automated risk factor/errors is comparatively less
then pre-processed in INSIGHT program to adjust the size, and has an ability to create any shape and geometrical
location and orientation of the model within the RP machine. features. In addition to this, patterns can be made hallow
Slicing of the model (which can vary from 0.01 mm to which is difficult in conventional and CNC fabrication. A
0.7mm) also is done to fix a deposition thickness of 0.124 detailed comparison between conventional, CNC and RP
mm. Tool path generation, support material (SR-30) fabrication methods to obtain master patterns is shown in
generation, assigning of material (ABS-M30) for building, Table 3.
are the other pre-processing steps done in INSIGHT. The
time taken to build the parts and the amount of building
material and the support material required for the parts can
be obtained from the software. Patterns thus built are
removed from the machine. Support material is cleaned and
the edges may be finished by filing if required.

Fig. 3 Photo micrographs obtained at 4X magnification (a)

III. DISCUSSION
ABS master pattern (b) wooden pattern.
Conventionally, impeller pattern is manufactured based
The dimensions of the fabricated wooden master pattern
on the dimensions and specifications in blue prints (2D
and ABS master pattern with respect to their aluminum
drawings). Conventional method of making patterns is a
castings were observed. Based on these observations, it is
tedious task, since it includes the usage of hand cutting tools
understood that there was a normal deviation on the
such as chisel, different sizes of saw etc. and requires an
dimensions in both the castings due to the shrinkage of
exact sequence of the tasks to form the complex master
aluminum alloy. However, it is observed that the contours of
pattern. On the other hand, pattern production using RP
casting (the edge of blades) made using wooden patterns
technology is computer automated which provides accurate
were not sharp enough or accurate compared to that of
shape and dimensions and avoids the need of joining
casting made using ABS pattern. A microscopic observation
individual blades.
was also made to understand the surface quality of the
Table 2: Lead time and cost comparison for conventional
method with RP method
castings obtained using master patterns made of wood and
ABS. Photo micrographs obtained at 4X magnification
Conventio Rapid (Figure 3) shows smooth surface finish of ABS master
Production Details pattern compared to the wooden pattern. An increased
nal Method Prototyping
adherence of sand particles to the wooden master pattern can
Design time (hrs) 4 4
cause surface irregularities at a length scale of sand grains.
Fabrication time (hrs) 18 2.25
Based on the visual comparison, it can be suggested that the
Man Hours required roughness of the impeller casting can be reduced from RMS
16 8
(hrs) 125 to RMS 60 by replacing wooden master pattern to ABS
Total time (hrs) 22 6.25 master pattern.
Number of
40 – 60 300 - 450
castings/patterns IV. CONCLUSION
Total cost (INR) 300 600 The results of this study indicate significant advantages in
employing rapid prototyping technology in the production of
Lead time comparison of the fabrication of master patterns master patterns. These advantages include substantial cost
through conventional method and rapid prototyping and lead-time savings with minimal material wastage. In
technology is showed in Table 2. A reduced lead time of 65 addition to this, the accurate dimensions and enhanced
-70 % can be obtained using RP method in addition to the surface quality of castings (better than ISO N10
reduction in manpower in the production of master patterns. specification) obtained using ABS patterns eliminated
Although the total cost involved in RP method is twice that of secondary post-processing steps. The higher density and the
conventional method, considering the number of castings rigidity of ABS patterns may also increase the pattern life
which can be obtained using master patterns, four times which in turn contributes to more number of castings per

70
 ISSN: 2277-3754
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 1, Issue 4, April 2012
pattern and reduction in the total production cost. These making hollow patterns and opting for mass customization
benefits clearly indicate a wide scope for RP technology in through rapid manufacturing. It is envisaged that the
foundries. Though this technology has welcomed by introduction of economically viable materials and advanced
foundries in the production of value added castings, the usage additive manufacturing technology will potentially change
of RP technology in small and medium scale foundries is still the production volume of the castings, meeting the customer
in infancy stage due to high initial cost and the higher requirements.
material cost. But, RP technology can be economical by
Table 3 Comparisons between conventional, CNC and RP fabrication methods to obtain complex master patterns
Variables Conventional CNC Machining Rapid Prototyping
Forming process Subtractive manufacturing Subtractive manufacturing Additive manufacturing
process which requires skills, process which may also require process without much human
various tools, jigs & fixtures programming skills intervention or tooling

Operations Single operation only can be Simultaneous operations on Multiple operations are
performed at a time the pattern are restricted integrated in the pattern
building process

Post-Operations Secondary or tertiary Secondary machining Secondary operations are not

machining operations are operations may be required to required, as fine shaped pattern
required depending on the complete a pattern fabrication. is obtained.
complexity of the pattern
Tools Different types of cutting and Different types of cutting and No special tools are required
finishing tools are required to finishing tools are required to
form specific features and form specific features and
profiles on the pattern profiles on the pattern

CAD data CAD model is not required CNC tool path generation Time required to process a
based o on CAD data requires CAD data (STL format) for
more time to generate a program pattern building is very nominal

Risk factor/error very high risk factor since high risk factor while Risk factor during pattern
there can be manual errors machining the pattern building, is very less

Integral Features Integral features within the Forming integral features Integral features within the
pattern cannot be built within the pattern are limited pattern can be easily built

End product Single pattern at a time Single pattern at a time Multiple patterns at a time
Operator Compulsory until the Required for programming & May not be required, best
completion of job feeding the parts to CNC suited for web based
machine manufacturing

Nature of the Generally solid pattern can solid & hollow (depending on Solid and hollow
product only be obtained wall thickness) pattern can be (depending on wall thickness)
made patterns can be obtained

[4] Akarte, M.M. and B. Ravi, “RP/RT Route Selection for

REFERENCES Casting Pattern Development”, 19th AIMTDR, Chennai, Dec
2000.
[1] C. K. Chua, S. M. Chou and T. S. Wong, “A Study of the
State-of-the-Art Rapid Prototyping Technologies”, Int J Adv [5] Kalpakjian, S. and Schmid, S.: Manufacturing Processes for
Manuf Technol, Vol 14, pp 146-152, 1998. Engineering Materials, 5th Ed., Prentice-Hall, Englewood
Cliffs, NJ, 2007
[2] C.M. Cheah · C.K. Chua · C.W. Lee · C. Feng · K. Totong,
“Rapid prototyping and tooling techniques: a review of [6] ASM: Casting Design and Performance, ASM International,
applications for rapid investment casting”, Int J Adv Manuf 2009.
Technol , Vol. 25, pp 308–320, 2005.
[7] Stainless Foundry & Engineering, Inc: Investment Tolerances
[3] J.L. Songa, Y.T. Li, Q.L. Deng, D.J. Hu, Rapid prototyping (http://www.stainlessfoundry.com/InvestTol.asp), retrieved on
manufacturing of silica sand patterns based on selective laser 15/03/2012.
sintering, Journal of Materials Processing Technology
Vol.187–188, pp 614–618, 2007.

71
 ISSN: 2277-3754
International Journal of Engineering and Innovative Technology (IJEIT)
Volume 1, Issue 4, April 2012
AUTHOR BIOGRAPHY

Mr. Rajashekar Patil is working as an Assistant Professor in Mechanical

Engineering Department of Shri Dharmasthala Manjunatheshwara College of
Engineering & Technology, Dharwad, Karnataka, India. He was awarded his
Master of Technology Degree from UBDTCE, Davanagere, Karnataka. He is
pursuing his PhD from VTU,Belgaum. His areas of interest are Digital
Manufacturing, Collaborative Manufacturing, and Computer Aided
Engineering Drawing and Machine Drawing. He has 13 years of teaching and
eight years of research experience.. He has published more than 10 research
papers in journals and conferences. He has also guided ten postgraduate
students. He is also an author of computer aided engineering drawing text book
published by new age international, New Delhi and also co-author for A primer
on CAED, CAMD and question bank books published by Visvesvaraya
Technological University, Belgaum, Karnataka, India.

Dr. S. Mohan Kumar obtained Ph.D. degree from IIT Kharagpur. He is

currently working as Principal of Shri Dharmasthala Manjunatheshwara
College of Engineering & Technology, Dharwad, Karnataka, India. He has
more than 30 years teaching and 2 years of industry experience. His area of
research interest includes robotics, automation and collaborative
manufacturing. He has more than 90 research publications in various
international/national journals and conferences; he also co- authored text books
on computer aided engineering drawing and computer aided machine drawing.
He is recognized Ph.D. Supervisor for VTU, Belgaum, Karnataka in India and
presently guiding 06 Ph.D. scholars.

Dr. E. Abhilash obtained Ph.D.from NIT Calicut. He is currently working as

Associate Professor in Mechanical Engineering Department of Shri
Dharmasthala Manjunatheshwara College of Engineering & Technology,
Dharwad, Karnataka, India. He has more than7 years of research and 2 years of
industry experience. Casing Process Simulation and Advanced Materials
Technology are a few of his research topics. He has more than15 research
publications in various international/national journals and conferences; he has
participated in the Indian Foundry Roadmap project funded by National Centre
for Aerospace Innovation and Research, IIT Bombay. He also is a member of
Institute of Indian Foundrymen and Institution of Engineers India..

72