Date of Award

Summer 1994

Document Type

Thesis - Restricted

Degree Name

Master of Science (MS)

Department

Mechanical Engineering

First Advisor

Cariapa, Vikram

Second Advisor

Fournelle, Raymond

Third Advisor

Stango, Robert

Abstract

The last five years have seen vast increases in the use of Rapid Prototyping Systems. The casting industry, because of increasing world competition, alternative material advancements and an industry push towards reduced product lead times, would benefit from rapid prototyping. This thesis explores the feasibility of using patterns made by the stereolithography (SLA) process on a high speed sand molding system. Material propertie tests (tensile, compressive and hardness) were conducted on the stereolithography resin material in an environment similar to the actual industrial sand molding conditions. These were compared to properties of other more conventional pattern materials. Stereolithography patterns were made at Marquette University, mounted on a Disamatic sand molding machine at Briggs and Stratton Castings Division and ductile iron castings were made. The stereolithography patterns were periodically measured on a Coordinate Measuring Machine. Dimensional deviations that illustrated wear patterns were graphed and summarized. The feasibility and practicality of using stereolithography to create prototype patterns for high speed sand molding systems are discussed. In addition, it is concluded that stereolithography is viable for sand casting processes. But more development work is required to make the stereolithography process more reliable. At present, the output is highly dependent on the skill of the stereolithography operator.

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