Rapid Tooling

S.Senthilkumar AP/MECH

Topics to be covered
Basic concept Digitization techniques Model Reconstruction Data Processing for Rapid Prototyping: CAD model preparation, Data Requirements geometric modeling techniques: - Wire frame, surface and solid modeling data formats Data interfacing, Part orientation and support generation, Support structure design, Model Slicing and contour data organization, Direct and adaptive slicing Tool path generation

REVERSE ENGINEERING & MOLD DESIGN

Instrumentation Box - SHANKO Molds

3D Model Cover inner tray

Core and Cavity

Part Modeling by Reverse Engineering Core & Cavity Separation NC Code generation for Core & Cavity Tools used: CMM to collect Points Pro/ENGINEER Part Modeling, Mold Cavity Design

CASTING DESIGN RAPID TOOLING

Process Flow

Casting Model creation

Holes removed and machining allowance added

Core Creation
Cores are created with advance surface commands

Pattern Creation
Exhaust Manifold M&M Parting was done after merging core with core prints

Core Box creation

Core boxes were created -parting surface -split was done

Rapid model
Pattern 3D model is converted to STL

Tools used: Pro/ENGINEER Rapid prototype M/C Foundry Tools

Apron BoxBoxGRUNDFOS INDIA Pvt Ltd

Rapid Tooling - Pattern Making

FDM process is chosen and Pattern is made

Casting process
With Pattern and Core Mold cavity is made and Casting was created

S. Senthil Kumar

CASTING DESIGN
Housing LH & RH - Enfield

Casting Model

Casting Model with Core Casting Design Rapid Tooling

RP Model - Pattern

Castings

Tools used: Pro/ENGINEER Part Modeling, Cast Cavity Design

S. Senthil Kumar

CASTING DESIGN
Adaptor Housing & Cylinder Cover - TATA

Casting Design Rapid Tooling Tools used: Pro/ENGINEER Part Modeling, Cast Cavity Design

S. Senthil Kumar

S. Senthil Kumar