Additive Technologies in Foundries (FSI-PTS)

Academic year 2024/2025
Supervisor: Ing. Vladimír Krutiš, Ph.D.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:

In this subject, students will get acquainted with the preparation and use of data needed for 3D scanning of models and castings, for numerical simulations and virtual engineering. Students will learn about the basic methods and principles of the RAPID PROTOTYPING (RP) technology, including reverse engineering procedures (RE). They will get familiar with the selected modern technologies for manufacturing castings and process management methods with the application of the industry 4.0 principles. They will also learn model surfacing and smoothing procedures and methods for RP, molds and castings and they will get acquainted with the dimension and shape accuracy testing methods and metallographic and phase casting material assessment methods. Part of the subject will also be to obtain knowledge of the composition of production costs and the foundry production economy.

 

Students will acquire the knowledge and skills of 3D modelling (designing and making), rapid prototyping methods (RP), using computer technology for 3D measuring (scanning), numerical simulations of foundry procedures etc. Process management in selected foundry technologies including quality control and composition and production cost management in prototype production.
Learning outcomes and competences:
 
Prerequisites:
 
Course contents:

The course introduces students to basic approaches to data processing for models produced by the rapid prototyping (RP) method. They acquire basic knowledge of RP principles, including an overview of additive manufacturing (AM) methods applicable in foundry technology. They gain hands-on experience using AM for prototyping. The subject includes hybrid technologies, computer support for the production of molds and models, including quality control methodology and the economics of producing prototype castings.
Teaching methods and criteria:
 
Assesment methods and criteria linked to learning outcomes:
 
Controlled participation in lessons:
 
Type of course unit:
    Lecture  13 × 2 hrs. optionally                  
    Laboratory exercise  13 × 3 hrs. compulsory                  
Course curriculum:
    Lecture

  1. Foundry production – division of production technologies, technological nature of construction. Stress in castings - construction.

  2. Industry 4.0 – new technological challenges.

  3. CAD modeling – principles, methods and tools for creating 3D model drawings for RP methods and numerical simulation.

  4. Optimization of casting construction – topological optimization, generative design.

  5. Reverse engineering methods.

  6. Methods of 3D scanning and image processing.

  7. Additive technology - division, principles of individual methods.

  8. Additive production of foundry models.

  9. Additive production of metal materials.

  10. RP methods suitable for foundry practice, examples of use, achievable parameters.

  11. Surface treatment of models for RP, surface treatment of molds for selected modern technologies.

  12. Case studies, examples from practice.

  13. Economic aspects of prototyping using additive manufacturing.
    Laboratory exercise

1. - 3. Making 3D casting models and patterns using Solid Works software.
4. - 5. Model preparation for 3D printing - slicer.
6. - 8. 3D printing of selected projects.
8. - 12. Ceramic shell making, prototype pouring
13. Quality control of castings, evaluation.
Literature - fundamental:
1. FORD, S., MINSHALL, T. Invited review article: Where and how 3D printing is used in teaching and education. Additive Manufacturing. Volume 25, January 2019, Pages 13 -150. https://doi.org/10.1016/j.addma.2018.10.028
2. GIBSON, I., D. W. ROSEN a B. STUCKER. Additive manufacturing technologies: rapid prototyping to direct digital manufacturing. New York: Springer, c2010. ISBN 1441911200
3. MITCHELL, A. LAFONT, U., HOŁYŃSKA, M.,SEMPRIMOSCHNIG, C. Additive manufacturing - A review of 4D printing and future applications. Additive Manufacturing, Volume 24, December 2018, Pages 606-626. https://doi.org/10.1016/j.addma.2018.10.038
4. WANG, W., STAL, H. W., CONLEY, J. G. Rapid Tooling Guidelines For Sand Casting, Springer, 2010 ISBN 978-1-4419-5730-6.
5. CAMPBELL, J. Casting, Butterworth-Heinemann, Oxford, 2000, ISBN 0 7506 1696 2.
6. KAUFMAN, H. UGGOWITZER, P. J. Metalurgy and Processing of High-Integrity Light Metal Pressure Castings. Schiele-Schön, 2007, Berlin. ISBN 3-7949-0754-X
7. BOLONO, F., ODORIZZI, S. Numerical simulation of Foundry Processes, Program Leonardo da Vinci, 2001
8. Herman, A. a kol. Počítačové simulace ve slévárenství, Vydavatelství ČVUT, 2000
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
N-SLE-P full-time study --- no specialisation -- Cr,Ex 5 Compulsory 2 1 S