Login | Register

The Relationship Between Lattice Structure Topology and Rapid Investment Casting Performance

Title:

The Relationship Between Lattice Structure Topology and Rapid Investment Casting Performance

Richard, Christopher (2019) The Relationship Between Lattice Structure Topology and Rapid Investment Casting Performance. Masters thesis, Concordia University.

[thumbnail of Richard_MASc_S2021.pdf]
Preview
Text (application/pdf)
Richard_MASc_S2021.pdf - Accepted Version
4MB

Abstract

To leverage the unprecedented design freedom of additive manufacturing (AM), this work aims to develop a design methodology for lattice structures fabricated by rapid investment casting (RIC). What lattice topological properties have the most significant impact on the overall performance in RIC, and how to improve them? The hypothesis is that the relative strut size, number of joints, joint valence, and strut angle significantly affect the performance. There is no overarching analysis of the effect that lattice topology has on casting performance. To remedy this, various lattice topologies underwent mold flow simulation, finite element analysis, casting experiments, and grain structure analysis. From the results, a set of design guidelines for RIC is created, and new lattice structures are designed. The design recommendations by importance are as follows. A relative strut size, number of joints, and joint valence should be below 0.20, 9, and 8, respectively. For mechanical performance, the strut angle distribution should include vertical, diagonal, and horizontal struts. The two proposed topologies: proposed cell and hourglass, meet all these criteria and achieve good casting and mechanical performance.

Divisions:Concordia University > Gina Cody School of Engineering and Computer Science > Mechanical, Industrial and Aerospace Engineering
Item Type:Thesis (Masters)
Authors:Richard, Christopher
Institution:Concordia University
Degree Name:M.A. Sc.
Program:Mechanical Engineering
Date:16 September 2019
Thesis Supervisor(s):Kwok, Tsz-Ho
Keywords:Rapid Investment Casting, Lattice Structures, Lattice Topology, Design Guidelines
ID Code:988456
Deposited By: CHRISTOPHER RICHARD
Deposited On:27 Oct 2022 13:52
Last Modified:27 Oct 2022 13:52

References:

[1] Fei Li, Yingchun Wang, Donghong Wang, Yanjie Zhao, Chengkang Qi, and
Baode Sun. Comparison of various gating systems for investment casting of
hydraulic retarder impeller with complex geometry. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, page
0954405420971994, 2020.
[2] Jiangping Yu, Donghong Wang, Dayong Li, Ding Tang, Xin Hao, Shixin Tan,
Da Shu, Yinghong Peng, and Baode Sun. Engineering computing and data-driven
for gating system design in investment casting. Int. J. Adv. Manuf. Technol.,
111(3):829–837, 2020.
[3] Patrik Karlsson, Lars Pejryd, and Niclas Strömberg. Generative design optimization and characterization of triple periodic lattice structures in alsi10mg. In
International Conference on Additive Manufacturing in Products and Applications, pages 3–16. Springer, 2020.
[4] Lin Cheng, Jiaxi Bai, and Albert C To. Functionally graded lattice structure
topology optimization for the design of additive manufactured components with
stress constraints. Computer Methods in Applied Mechanics and Engineering,
344:334–359, 2019.
[5] Nesma T Aboulkhair, Marco Simonelli, Luke Parry, Ian Ashcroft, Christopher
Tuck, and Richard Hague. 3D printing of aluminium alloys: Additive manufacturing of aluminium alloys using selective laser melting. Progress in Materials
Science, 106:100578, 2019.
[6] Tobias Maconachie, Martin Leary, Bill Lozanovski, Xuezhe Zhang, Ma Qian,
Omar Faruque, and Milan Brandt. Slm lattice structures: Properties, performance, applications and challenges. Materials & Design, 183:108137, 2019.
[7] S. Leuders, S. Meiners, L. Wu, A. Taube, T. Tröster, and T. Niendorf. Structural components manufactured by selective laser melting and investment casting—impact of the process route on the damage mechanism under cyclic loading.
J. Mater. Process. Technol., 248:130 – 142, 2017.
[8] C. Li, Z.Y. Liu, X.Y. Fang, and Y.B. Guo. Residual stress in metal additive
manufacturing. Procedia CIRP, 71:348 – 353, 2018.
[9] V H Carneiro, S D Rawson, H Puga, J Meireles, and P J Withers. Additive manufacturing assisted investment casting: A low-cost method to fabricate periodic
metallic cellular lattices. Addit. Manuf, page 101085, 2020.
[10] Yingjie Huang, Yingying Xue, Xinfu Wang, and Fusheng Han. Effect of cross sectional shape of struts on the mechanical properties of aluminum based pyramidal
lattice structures. Materials Letters, 202:55–58, 2017.
[11] Hélder Puga, Vitor H Carneiro, P Correira, V Vieira, J Barbosa, and J Meireles.
Mechanical behavior of honeycomb lattices manufactured by investment casting
for scaffolding applications. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 231(1-2):73–81,
2017.
[12] Nimesh A. Khirsariya, M. S. Kagthara, and P. H. Mandalia. Reduction of shrinkage defect in valve body casting using simulation software. International Journal
of Engineering Sciences & Research Technology, 3(4):5021–5024, 2014.
[13] Rapid Investment Casting: Design and Manufacturing Technologies, volume Volume 1: 39th Computers and Information in Engineering Conference, 08 2019.
V001T02A022.
[14] Jenn-Kun Kuo, Pei-Hsing Huang, Hsin-Yi Lai, and Jian-Rong Chen. Optimal
gating system design for investment casting of 17-4PH stainless steel enclosed
impeller by numerical simulation and experimental verification. Int. J. Adv.
Manuf. Technol., 92(1-4):1093–1103, 2017.
[15] Donghong Wang, Jinyu Sun, Anping Dong, Da Shu, Guoliang Zhu, and Baode
Sun. An optimization method of gating system for impeller by rsm and simulation
in investment casting. Int. J. Adv. Manuf. Technol., 98(9-12):3105–3114, 2018.
[16] Maidin S, T.M. Yi, Hambali A, Suriati Akmal, Ruzy Hambali, and Zulkeflee
Abdullah. Investigation of optimum gating system design of fused deposition
modelling pattern for sand casting. J. Mechan. Eng. Sci., 11:2801–2814, 09 2017.
[17] P.-H. Huang and M.-J. Guo. A study on the investment casting of 17-4ph stainless
steel helical impeller of centrifugal pump. Mater. Res. Innov., 19(sup9):S9–77–
S9–81, 2015.
[18] Marek Bruna, Dana Bolibruchová, Richard Pastirčák, and Anna Remišová. Gating system design optimization for investment casting process. J. Mater. Eng.
Perform., 28(7):3887–3893, 2019.
[19] Santosh Reddy Sama, Tony Badamo, Paul Lynch, and Guha Manogharan. Novel
sprue designs in metal casting via 3D sand-printing. Addit. Manuf, 25:563–578,
2019.
[20] OMAR MOHD FAIZAN BIN MARWAH. Analysis of various rapid prototyping
techniques for investment casting. PhD thesis, Universiti Teknologi Malay, 2016.
[21] Jiayi Wang, Santosh Reddy Sama, Paul Carl Lynch, and Guhaprasanna
Manogharan. Design and topology optimization of 3D-printed wax patterns for
rapid investment casting. Procedia Manuf, 34:683–694, 2019.
[22] Muslim Mukhtarkhanov, Asma Perveen, and Didier Talamona. Application of
stereolithography based 3D printing technology in investment casting. Micromachines, 11(10):946, 2020.
[23] Jaspreet Singh, Rupinder Singh, and Harwinder Singh. Dimensional accuracy
and surface finish of biomedical implant fabricated as rapid investment casting
for small to medium quantity production. J. Manuf. Process., 25:201–211, 2017.
[24] OMF Marwah, S Sharif, M Ibrahim, EJ Mohamad, and MH Idris. Direct rapid
prototyping evaluation on multijet and fused deposition modeling patterns for investment casting. Proceedings of the Institution of Mechanical Engineers, Part
L: Journal of Materials: Design and Applications, 230(5):949–958, 2016.
[25] Yoshiki Ishida and Taira Miyasaka. Dimensional accuracy of dental casting patterns created by 3d printers. Dental materials journal, 35(2):250–256, 2016.
[26] Mario Monzon, Zaida Ortega, Alba Hernandez, Ruben Paz, and Fernando Ortega. Anisotropy of photopolymer parts made by digital light processing. Materials, 10(1), 2017.
[27] Pei-Hsing Huang and Wei-Ju Huang. Processing design of miniature casting incorporating stereolithography technologies. International Journal of Mechanical,
Aerospace, Industrial, Mechatronic and Manufacturing Engineering, 11(8):1403 –
1406, 2017.
[28] Parlad Kumar, Inderpreet S. Ahuja, and Rupinder Singh. Effect of process parameters on surface roughness of hybrid investment casting. Progress in Additive
Manufacturing, 1(1):45–53, Jun 2016.
[29] MN Hafsa, N Kassim, S Ismail, SA Kamaruddin, TM Hafeez, Batu Pahat,
M Ibrahim, and ZH Samsudin. Study on surface roughness quality of fdm and
mjm additive manufacturing model for implementation as investment casting
sacrificial pattern. Journal of Mechanical Engineering, 2018.
[30] Mustaffa Ibrahim and MN Hafsa. Dimensional accuracy of additive manufacturing model with different internal structure for investment casting implementation.
International Integrated Engineering Summit (IIES 2014), 2014.
[31] Munish Chhabra and Rupinder Singh. Experimental investigation of patternless casting solution using additive manufacturing technique. MIT International
Journal of Mechanical Engineering, 1(1):17–25, 2011.
[32] Jason Walker, Evan Harris, Charles Lynagh, Andrea Beck, Rich Lonardo, Brian
Vuksanovich, Jerry Thiel, Kirk Rogers, Brett Conner, and Eric MacDonald. 3d
printed smart molds for sand casting. Int. J. Metalcast., 12(4):785–796, 2018.
33] Yashkumar Patel, Ankit Kahar, and Dhaval Doshi. Technical Review of Additive
Manufacturing technique in Patternless Casting Manufacturing. Int J S Res Sci.
Tech., page 6, 2018.
[34] Amir M Aboutaleb, Mohammad J Mahtabi, Mark A Tschopp, and Linkan
Bian. Multi-objective accelerated process optimization of mechanical properties in laser-based additive manufacturing: Case study on selective laser melting
(slm) ti-6al-4v. Journal of Manufacturing Processes, 38:432–444, 2019.
[35] Oraib Al-Ketan, Reza Rowshan, and Rashid K Abu Al-Rub. Topologymechanical property relationship of 3D printed strut, skeletal, and sheet based
periodic metallic cellular materials. Addit. Manuf., 19:167–183, 2018.
[36] Zhen Wang, Zhiyu Xiao, Ying Tse, Chuanshou Huang, and Weiwen Zhang. Optimization of processing parameters and establishment of a relationship between
microstructure and mechanical properties of slm titanium alloy. Optics & Laser
Technology, 112:159–167, 2019.
[37] Li Tang, Qingbiao Zhang, Keshan Liang, Xiqing Zhao, and Zhixiong Zhang. Discrete optimization of internal part structure via slm unit structure-performance
database. Metals, 8(1):45, 2018.
[38] Lina Yan, Li Ping Zhao, and Gavin Kane O’Neill. Dimensional consistency of
SLM printed orthopaedic implants designed using lightweight structures. Transactions on Additive Manufacturing Meets Medicine, 2(1), 2020.
[39] Han Wang, Yu Fu, Mingming Su, and Hai Hao. A novel method of indirect rapid
prototyping to fabricate the ordered porous aluminum with controllable dimension variation and their properties. Journal of Materials Processing Technology,
266:373–380, 2019.
[40] Dawei Li, Wenhe Liao, Ning Dai, Guoying Dong, Yunlong Tang, and Yi Min
Xie. Optimal design and modeling of gyroid-based functionally graded cellular
structures for additive manufacturing. Comput. Aided Des., 104:87–99, 2018.
41] Marius A Wagner, Thomas S Lumpe, Tian Chen, and Kristina Shea. Programmable, active lattice structures: Unifying stretch-dominated and bendingdominated topologies. Extreme Mechanics Letters, 29:100461, 2019.
[42] Enrique Alabort, Daniel Barba, and Roger C Reed. Design of metallic bone by
additive manufacturing. Scripta Materialia, 164:110–114, 2019.
[43] Ajeet Kumar, Luca Collini, Alix Daurel, and Jeng-Ywan Jeng. Design and additive manufacturing of closed cells from supportless lattice structure. Additive
Manufacturing, page 101168, 2020.
[44] Ahmed Hussein, Liang Hao, Chunze Yan, Richard Everson, and Philippe Young.
Advanced lattice support structures for metal additive manufacturing. Journal
of Materials Processing Technology, 213(7):1019–1026, 2013.
[45] Benjamin Vaissier, Jean-Philippe Pernot, Laurent Chougrani, and Philippe
Véron. Genetic-algorithm based framework for lattice support structure optimization in additive manufacturing. Computer-Aided Design, 110:11–23, 2019.
[46] Renkai Huang, Ning Dai, Xiaosheng Cheng, and Lei Wang. Topology optimization of lattice support structures for heat conduction in selective laser melting.
The International Journal of Advanced Manufacturing Technology, 109(7):1841–
1851, 2020.
[47] Ajeet Kumar, Saurav Verma, and Jeng-Ywan Jeng. Supportless lattice structures
for energy absorption fabricated by fused deposition modeling. 3D Printing and
Additive Manufacturing, 7(2):85–96, 2020.
[48] Sarojrani Pattnaik, D Benny Karunakar, and PK Jha. Developments in investment casting process—a review. Journal of Materials Processing Technology,
212(11):2332–2348, 2012.
[49] Sarojrani Pattnaik, Pradeep Kumar Jha, and D Benny Karunakar. A review
of rapid prototyping integrated investment casting processes. Proc. Inst. Mech.
Eng. Pt. L J. Mater. Des. Appl., 228(4):249–277, 2014.
[50] Rupinder Singh, Sunpreet Singh, and Prince Kapoor. Investigating the surface
roughness of implant prepared by combining fused deposition modeling and investment casting. Proceedings of the Institution of Mechanical Engineers, Part
E: Journal of Process Mechanical Engineering, 230(5):403–410, 2016.
[51] Daljinder Singh, Rupinder Singh, and Kamaljit Singh Boparai. Development
and surface improvement of fdm pattern based investment casting of biomedical
implants: A state of art review. J. Manuf. Process., 31:80 – 95, 2018.
[52] Marta Revilla-León and Mutlu Özcan. Additive manufacturing technologies used
for 3d metal printing in dentistry. Current Oral Health Reports, 4(3):201–208, Sep
2017.
[53] Bjorn Einar Dahl, Hans Jacob Ronold, and Jon E. Dahl. Internal fit of single
crowns produced by cad-cam and lost-wax metal casting technique assessed by
the triple-scan protocol. The Journal of Prosthetic Dentistry, 117(3):400 – 404,
2017.
[54] H Wu, D Li, Y Tang, N Guo, F Cui, and B Sun. Rapid casting of hollow turbine
blades using integral ceramic moulds. Proc. Inst. Mech. Eng. B. J. Eng. Manuf.,
223(6):695–702, 2009.
[55] Haihua Wu, Dichen Li, Xiaojie Chen, Bo Sun, and Dongyang Xu. Rapid casting
of turbine blades with abnormal film cooling holes using integral ceramic casting
molds. Int. J. Adv. Manuf. Technol., 50(1-4):13–19, 2010.
[56] Julio Aguilar, Andre Schievenbusch, and Oliver Kättlitz. Investment casting
technology for production of tial low pressure turbine blades – process engineering
and parameter analysis. Intermetallics, 19(6):757 – 761, 2011.
[57] C.-D. Matte, M. Pearson, F. Trottier-Cournoyer, A. Dafoe, and T. H. Kwok.
Automated storage and active cleaning for multi-material digital-light-processing
printer. Rapid Prototyping J., 25(5):864 – 874, 2019.
[58] Nathaniel Després, Edward Cyr, and Mohsen Mohammadi. A performance metric
for additively manufactured microlattice structures under different loading conditions. Proceedings of the Institution of Mechanical Engineers, Part L: Journal
of Materials: Design and Applications, 233(9):1814–1829, 2019.
[59] Yanpeng Wei, Bo Yu, Quanzhan Yang, Peng Gao, Zhiquan Miao, Jingchang
Cheng, and Xun Sun. Damping behaviors of steel-based kelvin lattice structures
fabricated by indirect additive manufacture combining investment casting. Smart
Materials and Structures, 29(5):055001, 2020.
[60] Chuanlei Li, Hongshuai Lei, Zhong Zhang, Xiaoyu Zhang, Hao Zhou, Panding
Wang, and Daining Fang. Architecture design of periodic truss-lattice cells for
additive manufacturing. Addit. Manuf, page 101172, 2020.
[61] Wen Chen, Seth Watts, Julie A Jackson, William L Smith, Daniel A Tortorelli,
and Christopher M Spadaccini. Stiff isotropic lattices beyond the maxwell criterion. Science advances, 5(9), 2019.
All items in Spectrum are protected by copyright, with all rights reserved. The use of items is governed by Spectrum's terms of access.

Repository Staff Only: item control page

Downloads per month over past year

Research related to the current document (at the CORE website)
- Research related to the current document (at the CORE website)
Back to top Back to top