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TOOL PATH PLANNING FOR INVESTMENT

CASTING OF FUNCTIONAL PROTOTYPES /
PRODUCTION MOLDS

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 Technical Paper Presented at
National Conference on Investment Casting, September 22-23, 2003, CMERI,
Durgapur

TOOL PATH PLANNING FOR INVESTMENT CASTING OF

FUNCTIONAL PROTOTYPES / PRODUCTION MOLDS

Nagahanumaiah1, B. Ravi2, N.P. Mukherjee1

1
Scientist, Central Mechanical Engineering Research Institute, Durgapur
2
Associate Professor, Mechanical Engineering Department, IIT Bombay, Mumbai.

ABSTRACT

Presently, Investment casting plays a significant role in rapid manufacturing of

complicated geometries of product or mold for other near net shape
manufacturing. This paper evolved an alternative ways to develop an expendable
pattern and /or associated tooling for investment casting. Integration of Rapid
Prototyping (RP) with little other conversion or machining processes derives
significant number of tooling paths for investment casting. However, at present
many of these tool paths have certain inherent technical limitations, which are
material and process specific. Therefore, in rapid tooling development the current
challenge lies in combining strength, accuracy, and surface finish along with cost
competitiveness. In this paper an attempt has been made to quantify the process
capabilities from technical and business point of view. The issues associated with
these tooling routes are described along with few industrial examples and
identified the directions for future research. The spin-off advantage of these tool
paths in developing rapid hard tooling for injection molding and pressure die-
casting is also discussed.

KEYWORDS
Tooling, Investment Casting, Rapid Manufacturing, Expendable Pattern

1. INTRODUCTION Tooling development finds significant growth

At present, the concept of direct/ net shape
manufacturing is gaining much importance in the
context of lead-time and cost reduction. Many of
the injection moldings are being produced as
ready to assembly stage. However, in metal
casting, the concept of net shape manufacturing
is still evolving [Campbell, 2000]. Castings are
usually manufactured to near net shape and then
finished for assembly. Precision casting methods
such as investment casting and pressure die-
casting enable near net shape parts. The need for
part-specific tooling is however, a major
bottleneck, especially when production
requirement is low.
during last decade. As rapid prototyping (RP)
technologies justified their existence by its
special characteristics of producing 3D
model/part without any special tooling, its
application is widely explored in die and mold
development, i.e. Rapid Tooling (RT). Injection
molding and investment casting are the two
major processes, which find maximum rapid
tooling applications. This paper derives different
tool paths for investment casting. The benefits
and issues associated with rapid tooling
application in investment casting are analyzed
with industrial examples. The spin off
application of RP- integrated investment casting
in rapid hard tooling development, which is
being authors currently investigating is also
discussed.
2. INVESTMENT CASTING PROCESS
Investment casting, which was referred as lost
wax process in the ancient years is currently
regarded as precision casting next to pressure die
casting. Until mid eighties its application in
engineering component development was not
significant; in fact sand casting is highly used
metal casting process even today. However, in
the present scenario, investment-casting
application is rapidly increased specifically for
near net shape manufacturing of complex and
small engineering components. Investment
casting process follows the sequence shown in
figure 1.
Even though investment casting is used
considerably, the data available on allowable
tolerance is not well established. The common
notation used while designing a product for
investment casting is consideration of ±5% on
linear dimension. However, accuracy of
investment casting depends on many factors like:
pattern shrinkage, metal shrinkage, pattern
distortion, size, shape, tree construction, gating,
and expansion of ceramic shell during dewaxing
and sintering. Many industries and few
researchers have established these values through
their experience. Table 1 shows one such
database for linier tolerances.

Figure 1: Investment casting process sequence

Table 1: Linear tolerances as a function of casting size (Source: Metrocast Italiana s.p.a, Italy)
3. TOOL PATHS FOR INVESTMENT bottleneck in this route presently this problem is
CASTING solved by modified LOM technology, designed
especially for lost pattern production, called
In investment casting, tooling comprises the wax "Lost paper", generated objects that do not
pattern and associated tooling. Conventionally expand and do not crack the shell during the burn
wax patterns were manufactured using machined cycle [www.uni.edu]. Figure 2 shows some of
aluminimum of steel mold by injection molding. the investment castings produced by these direct
Over the year, the application of rapid methods at University of Northern Iowa, USA. .
prototyping technologies in investment casting is
emerged as strategic solution to produce the
functional metal prototypes rapidly with
relatively better quality. The journey in these
developments started early in 1990s and
presently direct and indirect tooling methods
SLA Quick cast
have been explored, which are discussed in the
next sections.

Initially, stereolithography epoxy models were

used as expendable pattern, which ultimately
burnt at open fire or autoclave to make the
ceramic mold [Jacob, 1996]. However, it results
in ceramic shell cracking due to outward LOM expendable paper
expansion SLS model during investing. This
leads the concept of developing the SLS models
with weaker web structure, which are widely
known as SLS quick cast models is started
around 1996. SLA quick cast models were
successfully used as expendable pattern, shell
cracking problems was solved to a great extent
due to the inward buckling of SLA quick cast
model while investing. Currently, this process
received well acceptance, many of the SLS plastic
researchers were studied insight of this process.
Yao has analyzed the shell cracking in Figure 2: Few examples for direct application
investment casting using thermo coupled of RP models as expendable pattern [Yury, et
mechanical FEM analysis [Yao, et al, 1999]. al, 2002]
Ferreira has studied furthermore on this shell
cracking problems experimentally, which leads In parallel, the indirect rapid tooling methods are
to the optimum web structure design of SLA also explored to produce more number of
quick cast pattern [Ferreira, et al 2003]. investment castings. Silicon rubber mold, LOM
Similarly, FDM wax models, FDM polystyrene direct mold, SLS direct mold, and spray metal
models are also used as expendable pattern in mold are most popular indirect rapid tooling
investment casting. However, the research methods explored in producing conventional
progress in this route is relatively less. CMERI wax patterns for investment casting of metal
has developed many engineering components inserts.
using these two routes for industrial applications.
Two wheeler’s engine cylinder head, crank lever, Therefore, with detailed study, we summarized
body of rifles are few important products to alternative tooling paths for investment casting
mention. These direct methods are expensive, as shown in figure 3. Implementation of spray
when the requirements are more than two. In metal tooling in production of functional
addition LOM paper models are also attempted prototypes by investment casting is studied
to use them as expendable pattern, however, experimentally and comparisons have been made
water absorption while ceramic scouting and ash with steel mold. This has been discussed in
removal during investing are the major section 4.
 Figure 3: Rapid Tool paths for investment casting
4. INDUSTRIAL EXAMPLES
The first author along with other CMERI
scientists studied the possibility of application of
spray metal tooling in injection molding of wax
pattern. Figure 3 shows the major steps used in
this project for rapid development of investment
castings. SLA RP model was used as master
pattern for developing spray metal tooling.
About 1000 wax patterns were produced from
this spray metal mold with minimum lead-time
of 7 days. However, presently these molds have
certain limitations in terms of accuracy, surface
finish and also difficulty in accommodating
differential shrinkage allowance. Therefore, the
production tooling (steel mold) was developed
using computer integrated manufacturing setup
at CMERI. The dimensional comparisons in both
cases are provided in table 2.
 Figure 4: Rapid development of investment casting

Table 2: Dimensional comparison of spray metal mold, steel mold and respective wax pattern and
castings
Original Spray Metal Mold Steel (machined) Mold
CAD RP Mold Wax Casting % Mold Wax Casting % age
Model Model pattern error pattern error
1 2 3 4 5 6 7 8 9 10
138.50 141.76 141.70 141.40 139.30 +0.57 141.68 141.28 139.20 +0.50
127.00 129.80 131.18 129.42 127.62 +0.48 129.92 129.56 127.46 +0.36
22.00 22.50 23.14 22.94 22.68 +3.09 22.50 22.38 22.14 +0.63
12.50 12.71 13.45 13.24 13.14 +5.12 13.28 12.90 12.70 +1.60
11.50 11.54 11.58 11.46 11.20 -2.60 11.96 11.80 11.60 +0.86
51.50 51.58 52.06 52.25 51.90 +0.77 52.68 52.40 52.00 +0.97
17.00 17.43 17.76 17.66 17.40 +2.35 17.39 16.92 16.78 -1.29
20.50 20.68 20.80 20.00 19.80 -3.41 21.97 21.22 20.80 +1.46
67.00 68.90 68.87 68.50 67.20 +0.29 6854 68.40 67.40 +0.59
20.70 21.00 21.20 20.50 19.58 -5.41 22.00 21.80 21.36 +2.89
22.60 22.94 22.95 22.84 22.64 +0.17 23.11 22.80 22.65 +0.22
24.50 24.86 24.94 24.72 24.72 -1.14 25.06 24.80 24.58 +0.32
Average % age error = ∑ col. (6) / 12 = -1.92 Average % age error = ∑ col. (10) / 12
= +0.75

5. ISSUES AND CHALLENGES processes involve a change of phase.

Even though, many case studies demonstrated
the success of rapid tooling application in
investment casting, available knowledge related
to process capability is not generic data and the
real benefits of these tooling paths is yet to be
quantified. When foundry engineer considers
rapid tooling process for investment casting of
functional prototypes, following issues arises.
Shrinkage prediction: It is widely
acknowledged that all molding and casting
Specifically, a liquid material may be
transformed from liquid to solid or in some cases
from solid to liquid and then back to solid again.
Also in rapid prototyping and tooling processes,
similar phase change phenomenon occurs. For
example
1. In Sterolithography (SLA) process liquid
photopolymers are get solidified by scanned
ultraviolet laser radiation
2. In Solid Ground Curing (SGC) process
liquid photopolymers are solidified by flood
ultraviolet radiation.
3. In Selective Laser Sintering (SLS) process
thermo plastic powder or polymer coating on
metal powder, in some cases direct metal
powder are melted by infrared laser radiation,
cooled and solidified
4. In Fused Deposition Modeling (FDM) process
thermo plastic or wax are melted, extruded,
cooled and solidified.
In each case, the phase change from liquid to
solid involves a decrease in specific volume and
resulting shrinkage. The total volumetric
shrinkage varies from process to process and
material to material, for a given process.
Therefore, when direct and indirect RT methods
used for expendable patterns, it is essential to
consider shrinkage at all the stages, which are yet
to quantify in many of the processes. In fact even
in investment casting the prediction of shrinkage
is not well established. Moreover, adding
differential shrinkage on the initial CAD model
is difficult with present CAD packages.
Distortion: Distortion is the primary issue, when
one considers the RP models as expendable
pattern for investment casting. For example,
SLA quick cast model is a hollow model, having
weaker web structures, which are more prone to
distort during dipping in ceramic slurry. LOM
models are more susceptible to water absorption,
which results in unpredictable distortion in many
cases.
Investing: Burnout process of RP model is still
more or less trial and error approach. However,
the phenomenon of investing is highly
thermodynamic problem, which needs extensive
study. Therefore, at present stage, removing the
ashes, selecting burnt-out process, temperature,
range, steam pressure settings are more or less
experience dependent.
Geometric compatibility: As geometric
compatibility of many RP processes is yet to
establish, selection of suitable rapid tooling
processes for development of expendable pattern
for investment casting is still unsolved problem.
This needs an extensive experimental
investigation supported with analytical models.
In addition to above, there are other minor
issues, which are either process specific or
depends on requirements. For example,
breakeven point for cost effectiveness, error
generation and propagations, are few other
important issues to mention.
6. RAPID HARD TOOLING
DEVELOPMENT: A SPIN-OFF
APPLICATION
At present, application of RP models as
expendable pattern in investment casting is
proved most cost effective and as well as rapid in
developing metal prototypes. Few researchers
are working towards extending this expertise in
production of permanent molds. We initiated a
project on rapid hard tooling development of
injection molding and pressure die-casting. In
this project development of hard tooling through
RP integrated investment casting, is one of the
primary objective.
Injection molds and pressure die casting dies
demands closer dimensions. It is indicated that
more than 30 parameters contributes to the final
accuracy. However, very few have significant
effect. Material shrinkage is one such common
variable, which is again depends on many other
process variables. Moreover, when one think of
using any RT processes, sufficient shrinkage
allowance has to be added to the CAD model.
On the other hand, these are relatively bulky;
therefore the current challenge lies in
development of shrinkage compensation model
for incorporating into the CAD model to be used
at initial RP stage. Furthermore, these processes
are not straightforward. Figure 5 shows the
process sequence for direct and indirect methods.
 Figure 3: RT flow chart. Top: direct RT, Bottom: indirect RT
(NB: Conversion of RP model into mold inserts may be possible in single stage or multi stage RT
processes)
In RT process chain dimension of out coming
model/part from one stage will be the input
dimension for succeeding process. Therefore,
total shrinkage allowance to be added to the
CAD model is given by the equation
n n −1
S = ∑ Si − ∑ S i (S i +1 + Si + 2 + S i +3 + ... + S n )
i =1 i =1
Where,
S = total shrinkage compensation
S1, S2 …. Sn = Shrinkage in stages 1… n
respectively (from RP to final part production)
In the proposed RP integrated investment casting
process for manufacturing of dies and molds, we
need to develop shrinkage of RP expendable
pattern and as well as shrinkage of metal mold
inserts at investment casting. Majority of the
previous research works concentrated on
influence of process parameters on shrinkage
[Wang, et al 1996]. The most common
methodologies used in these studies are either
statistical analysis or coupled thermo-mechanical
FEM analysis [Jean, 2003]. We are currently
investigating the shrinkage compensation for
following processes: SLA, FDM, SLS and
investment casting using RP models as patterns
to complete four alternative rapid hard tooling
processes, which we are studying in this project.
We are using geometry as main variable to
predict the shrinkage in all above processes, by
assuming optimized process parameters are
being used and material as constant. This
prediction will help the designer to optimize his
design early in product development cycle.
7. CONCLUSIONS
Application of rapid tooling methods for
producing expendable patterns shows significant
promise for lead-time reduction. At present,
direct methods like SLA quick cast, FDM wax
and polystyrene, SLS polymer, LOM expendable
paper models are used as expendable patterns in
investment casting. However, removal of ashes,
selection of investing processes parameters,
distortion of RP pattern, etc. becomes critical
issues. Indirect approach is relatively better,
where above problems are solved by producing
the conventional investment casting grade wax
patterns. Spray metal tooling, silicon rubber
molding, and SLS direct mold are few important
indirect RT methods used for this purpose. As an
evaluation, one industrial example is
demonstrated for application of spray metal mold
and compared its performances with
conventional steel molds. The spin off
application of this RP integrated investment
casting in producing hard tooling for injection
molding and pressure die casting is discussed.
The author’s present research, which is focused
on this application and development of shrinkage
compensation model for SLA, FDM, SLS and
investment casting considering geometric feature
as variable, keeping optimized process
parameters as constant is also discussed. In
summary, at present, when foundry engineer
considers RT application for investment casting
the issues like, shrinkage compensation,
distortion, investing process selection and
geometric compatibility arises as major issues,
which needs significant and dedicated research.
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