Development of optimised process chain for direct rapid tooling for casting processes with the application of three dimensional printing (3DP) was researched in this thesis. Optimisation was conducted from the aspect of optimal parameters defining of pre-processing, processing, and post-processing on improvement of mould’s characteristics, as well as introduction of rapid casting solutions made with minimalization of mould material consumption (achievement of casting in ZCast moulds and ZCast moulds with reduced wall thickness – shell casting). The aim was to get functional ZCast casting in shortest possible time and at the lowest cost.
Motivation for research was discussed in the introduction, and short review of previous researches on justification of application i.e. applicability of 3DP procedure in the area of direct rapid tooling. In this part of thesis’ hypotheses were set and methodology of experimental part of the thesis was defined.
Short review of RP system basics was given hereafter in the thesis where it was defined that technologies of rapid prototyping within numerous of applications present a significant step forward because they shorten production time and cost i.e. they eliminate expensive phases that were so far present in the phases of new products’ moulding. However, certain limitations were identified and seen primarily in number of available RP materials and their characteristics, and need for RP parts that are produced in additional post-processing.
Specifics of rapid tooling were described in the fourth part i.e. multicriteria division of RT procedures with demonstration of main characteristics defined in RT procedure was presented. In addition, the applicability of 3DP process in the area of casting within indirect and direct RT processes was demonstrated.
In the fifth, experimental part of the thesis, the influence of construction direction, as well as parameters of thermal treatment of ZCast materials on strength for stretching, bending and pressure, as well as on surface quality i.e. dimensional accuracy ZCast parts were researched. The conduction of experiments in RP and RE laboratories at the Faculty of Mechanical Engineering in Tuzla was described. The experiments were conducted in accordance with broadly defined scope of variations of parameters treatment. With the purpose of defining mathematical models of dependency of researched sizes on treatment’s parameters rotatable centrally positioned composite plan of experiment was also defined. Statistical processing of measuring results for CCD points was conducted and mathematical models of dependency were defined. Graphical description of measurement results of researched sizes for all defined experimental points was given that ensured comparative analysis of functional dependencies based on realistic and model calculated values.
Upon evaluation of ZCast501 moulding material in the previous chapter, in the sixth experimental part of the thesis applicability of ZCast casting mould of light metals such as aluminium was researched. Experimental plan is defined, experimental sample was chosen and experimental steps and research methodology of ZCast casting mould were defined. With the aim of cost optimisation of ZCast501 mould material for make of functional mould the possibility of gravity casting in ZCast mould and ZCast shells were researched. The moulds are made as binary ones, which was a requirement that was conditioned by the set hypotheses and research aim, meaning that comparative analysis of quantitative and qualitative characteristics of castings produced on the foundation of an approach based on conventional sand casting and application of approach based on ZCast casting.
At the end of this thesis conclusive discussions were made and lacks of personal research were identified and based on acquired discoveries the directions of further research were suggested.
Key words: three dimensional printing, direct rapid tooling, thermal treatment, ZCast casting, optimization