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Open JW Masters Final Thesis.Pdf The Pennsylvania State University The Graduate School Engineering Design, Technology, and Professional Programs PART DESIGN AND TOPOLOGY OPTIMIZATION FOR RAPID SAND AND INVESTMENT CASTING A Thesis in Engineering Design by Jiayi Wang 2017 Jiayi Wang Submitted in Partial Fulfillment of the Requirements for the Degree of Master of Science December 2017 The thesis of Jiayi Wang was reviewed and approved* by the following: Guha P. Manogharan Assistant Professor of Mechanical and Nuclear Engineering Thesis Co-Advisor Timothy W. Simpson Paul Morrow Professor of Engineering Design and Manufacturing Thesis Co-Advisor Sven G. Bilén Professor of Engineering Design, Electrical Engineering, and Aerospace Engineering Head of School of Engineering Design, Technology, and Professional Programs *Signatures are on file in the Graduate School iii ABSTRACT The integration of additive manufacturing into traditional metal casting provides a wide range of rapid casting solutions. One important motive for rapid casting is additive manufacturing’s ability to create highly complex objects without any fixture or tooling requirements. Such advantages provide great design freedom for the geometry of cast metal parts. The objective in this thesis is to explore the part design opportunistic and restrictions of two rapid casting processes: (1) sand casting with 3D Sand Printing-fabricated molds and (2) investment casting using material extrusion–fabricated wax-like patterns. Knowledge-based design guidelines are developed for both of these rapid casting processes through novel integration of topology optimization with design for casting and design for AM principles. For each process, a case study is conducted in which a mechanical metal benchmark is topologically optimized and redesigned following the proposed design rules. The redesigned parts are successfully cast and demonstrate improvements in mechanical performance and weight reduction. Keywords: additive manufacturing, 3D Sand Printing, material extrusion, topology optimization, rapid casting, sand casting, investment casting, cast part design iv TABLE OF CONTENTS LIST OF FIGURES ................................................................................................................. vi LIST OF TABLES ................................................................................................................... ix ABBREVIATIONS ................................................................................................................. x ACKNOWLEDGMENTS ....................................................................................................... xii Chapter 1 INTRODUCTION AND LITERATURE REVIEW .............................................. 1 1.1. Introduction to Additive Manufacturing ................................................................... 1 1.2. Introduction to Topology Optimization ................................................................... 6 1.3. Introduction to Traditional Metal Casting ................................................................ 10 1.4. Part Design for Traditional Metal Casting ............................................................... 13 1.5. Rapid Casting ........................................................................................................... 20 1.6. Thesis Overview ....................................................................................................... 22 Chapter 2 REDESIGN OF TRADITIONAL METAL PARTS FOR 3D SAND PRINTING USING TOPOLOGY OPTIMIZATION ...................................................... 24 2.1. Introduction .............................................................................................................. 24 2.2. Literature Review ..................................................................................................... 28 2.3. Methodology ............................................................................................................ 31 2.3.1. Step 1: Prepare the 3D CAD model for a metal part ..................................... 33 2.3.2. Step 2: Perform TO for the initial CAD model ............................................. 33 2.3.3. Step 3: Refinement and revision of the optimization output ......................... 34 2.3.5. Step 5: Perform FEA on the revised design .................................................. 42 2.3.6. Step 6: Analyze FEA results ......................................................................... 42 2.3.7. Step 7: Finalize the optimized geometry ....................................................... 42 2.4. Case Study ................................................................................................................ 43 2.4.1. TO and FEA validation ................................................................................. 43 2.4.2. Rigging design and casting ........................................................................... 46 2.4.3. Mechanical testing ......................................................................................... 48 2.5. Discussion ................................................................................................................ 49 2.6. Future Work ............................................................................................................. 50 Chapter 3 REDESIGN AND TOPOLOGY OPTIMIZATION OF TRADITIONAL METAL PARTS FOR INVESTMENT CASTING WITH 3D-PRINTED WAX PATTERNS ..................................................................................................................... 51 3.1. Introduction .............................................................................................................. 51 3.2. Literature Review ..................................................................................................... 55 3.3. Methodology ............................................................................................................ 57 3.3.1. Step 1: TO of the initial CAD ....................................................................... 58 3.3.2. Step 2: Redesign of the optimization output ................................................. 59 v 3.3.3. Step 3: FEA validation .................................................................................. 67 3.3.4. Step 4: Patterning of the optimized design .................................................... 68 3.4. Case Study ................................................................................................................ 68 3.4.1. TO and FEA validation ................................................................................. 68 3.4.2. Gating design and casting.............................................................................. 71 3.5. Discussion ................................................................................................................ 75 3.6. Future Work ............................................................................................................. 76 Chapter 4 CONCLUSIONS AND FUTURE WORK ............................................................. 78 4.1. Conclusions .............................................................................................................. 78 4.2. Future Work ............................................................................................................. 80 REFERENCES ........................................................................................................................ 82 vi LIST OF FIGURES Figure 1-1: Industries served and approximate revenues for additive manufacturing, 2016 [6]. .................................................................................................................................... 2 Figure 1-2: Material extrusion AM process principle and schematic [10]. ............................ 3 Figure 1-3: Binder jetting AM process principle and schematic [13]. .................................... 4 Figure 1-4: Sizing, shape, and topology optimization [22]. .................................................... 6 Figure 1-5: The influence of penalization factor p on topology optimization results [27]. .... 9 Figure 1-6: The general procedure of topology optimization based on SIMP algorithm [31]. .................................................................................................................................. 9 Figure 1-7: Sand mold assembly [34]. .................................................................................... 11 Figure 1-8: Traditional sand casting process [35]. .................................................................. 12 Figure 1-9: Schematic of the traditional investment casting process [41]. ............................. 13 Figure 1-10: Corner and edge on cast part: (a) bad design; (b) improved design [45]. .......... 15 Figure 1-11: Section change on cast part: (a) bad design; (b) and (c) improved designs [46]. .................................................................................................................................. 15 Figure 1-12: Intersection on cast part: (a) bad design; (b) and (c) improved designs [45]. .... 16 Figure 1-13: Pattern designed (a) without draft and (b) with draft [45]. ................................ 18 Figure 1-14: (a) Pattern with undercut; (b) and (c) improved designs [45]. ........................... 19 Figure 1-15: Rapid sand casting solutions: approaches and corresponding AM processes [49]. .................................................................................................................................
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