high precision casting by harshukh bhatti
TRANSCRIPT
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Harshukh BhattiDirector,Trauma Engineering Services.
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Lost Wax/Invest Process History stretches backward beyond the Egypt’s Pyramids/ China / Dwaper Yug of lord Krishna in Artisana and High precision ,Precious and artistic Jewelry & Gold Ornament manufacturing Which remain most popular technique today also . . . .After Dark Ages,Ebullient sculptor & Gold Founder (1766 B C) Benevenuo Cellini claim fascinating autobiography How he make use of “ Lost Wax “which he learned from a description by the Monk Thophilus Presbyter ( circa 1100)Creating Original artistic work on wax model,Coating with milky slurry,forming strong shell by successive coats,melting out wax and pouring a molten gold/silver.
World War II had Ignited development of this process due to sudden huge requirements of Aircraft /Military/ Automobile /ammunition parts mfg which eliminate machining-welding-assembly with high dimensional accuracy ,finish of complex geometry parts.
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* Casting Limitation 2.0 Gms to 45 Kilograms per Piece* Casting size 2 Cu mm to 610 Cu mm in size * Minimum Casting Wall thickness 1. 0 To 1.5 mm* Casting Surface finish 1.6/3.2 Micron /80-125 RMS* Delivery Minimum . . . . . . * Dimensional Accuracy>Normal/ +/- 0.2 mm up to 25 mm &+/- 0.1 with each
additional 25 mm thereafter >Premium/Coined +/- 0.15 mm up to 25 mm &+/- 0.08
with each additional 25 mm thereafter* Tolerance VDG-Markblatt P690 class D1 spec
IS -11166-1994* Die Tool Manufacturing Accuracy +/- 50 Micron &
Die Tool Assembly Accuracy +/- 50 MicronPreferable Tooling Manufacturing on CNC.
Harshukh BhattiDirector,Trauma Engineering Services.
8 to 12 week
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investment / lost wax casting process
1 Wax pattern Injection
2 Ejection Wax Pattern 1 2 3
3 Cluster Assembly with
casting Methoding.
4 Investing cluster or tree 4 5 6
5 Stucco,Reinforcing Coats
6 Shell Drying
7 De wax the shell mold
8 Firing the shell 7 8 9
9 Metal Pouring
10 Knock out & Fattling
11 Casting finishing 10 11
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StereolithographyStereolithography accurate and functional components for the philosophy of “ Test by Design ” base d on the I-DEAS 3D Modelling Software.
A highly accurate components are built up in layers as fine as 0.1 mm helping to ensure highest accuracy,as well as minimizing finishing time by SL 5195 resinspecifically formulated by CIBA Chemicals. The basic resins are Poly Urethane is a technique to produce extremely which have excellent component mechanical strength and good optical clarity, which proved as best prototype pilot model for development.BOING 777 is first world best Craft,100 % Design by 3D solid Modelling on the Globe. The Design Logic was
“Working Together”
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3D Solid Modelling for Vane Development
of Suction & Pressure
side of vane
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Vane Developmenton 3D Solid ModellingSoftware Master Cam I-DEAS Proengineer. . 3D Solid Modelling
Stereolithography
A defective vane for review
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Casting Horoscope. . Megma Software .
Metal contrection
Core support
Hot metal . . bouyancy
Runner/Riser
Volume &
location
Cool rate
Chaplets
ChillsCrack
& Tharmal crack Grain Structure& Micreo
Warpages & Destortion
Porosity Size &
location Cold Shut & Scab
Shrinkages
Location ,
Size
Hot Tears
Blow Holes
Alloying property, sadimentation & furnace charge
Weight,Volume &
Yeild
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SoftDietool
Technology
CNC cut Segment DieToolsImpeller Body Tool
Diffuser wax
Die tool
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Diffuser CNC WaxDie Tool
At bottom ActualComponent
Segment Die Tool for Pres/Suc vane of Impeller
Water Soluble segment CoreSoluble core disolve inwater flow and form a cavity of an Impeller
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IDP & IRDIE TOOLS FOR watersoluble segment core of closeImpeller for Internal cavity at IPCL TOOL ROOM .
All the Die Tools are manufactured on CNC Milling with a acuuracyof +/- 0.001” and assly tole of +/- 0.002 / 0.003“.
Die manufacturing stages:Die Design 3 D Modelling Die Split line Die Construction
Compound Die InsertDie Cooling Wax Pattern
Injection - Ejection DevicesComp’t Volume measurement
Weight Control On “IDEAS & MASTER CAM”software
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Open ImpellerDIE ToolCost 1.35 Lac
WAX Pattern with Wax + tool + MetalContraction
9 # Vane Incert Die Tools
425 mm Component Diameter
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Soluble segment core are placed in Impeller housing Wax Die for WAX Injection.Soluble wax & WAX pattern are kept in flowing water which dissolve soluble wax & causing cavity in the Impeller wax pattern thus forming vanes of an impeller.
WAX Injection Pressfor Making wax patterns at press. Of 3 to 4 kg/cm2Specially blended Industrial Wax
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Mr Carlo Grossi & Mr SubramaniamOn process presentation for Investment & Ceramic Precision casting Production.
Under control temperature18*C & Control rel Humidity.
Ceramic Injection press for making extra high Strength Core to withstand high buoyancy draught, Core lift ,Increase high temp. Core permeability and better Dimensional Control in Ceramic casting. Core segments are pasted to complete circular cavity.
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Wax Patterns Ready for Gating system and Methoding
TREE MAKINGIngates & RisersVenting ProvisionsChills/Chaplets provisionsCore supports (by pasting wax rods).Metal Yield 25 % to 35 %
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IMPELLER WAX PATTERNUnder Control Temperature
ready with all Methoding requirements byDesign /Method Dept.
WAX Pattern Tree ready for PRIME SHELL COAT
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Prime Shell CoatReinforcing Coats
Silca Bonding --buble Pan -Air strem from Bottam
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Prime Shell Coating
•Finish
•Bonding
•Adhesion to pattern
•Refractory Quality
•Zircon base •Flowability & Intricacy.
•Sharpness & clarity.
•Reinforcing of shell.
Secondary Shelling Coats . . . . . .
Quartz silica Colloidal silica Bonding Agents Reinforcing Coats Glass Wool Mat
under control temp.
CORE LIFT CONTROLReinforcing MediaCeramic sec”X I 0 Z ”Hollow Section insidethe cores 8 to 12 CoatMinimum 8/10 Hrs dryExtra strengthening ofshell to prevent bulging & ballooning
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IntricacyIn as cast condition 0.15mm Clearence bet’n outer Guide raw and 1st raw lug
Lost wax FeaturesKeyway4 mm hole 1 mm slittingOrientationBore within 0.1OD 110 mmWeight 1.63 kgFinish 95 rmsBalancing accu-racy +/- 5 gms/inch
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Ceramic Segments Assembly
Gravity Cast
Centrifugal Cast Core
Injected Casted Core
Reinforcing Core by
I,Z,X,O,H Section inside the core for restricting Bowing / lifting of Core.
Core assembled,locked,pasted and precured
Core repairs,
Core Locking
Core placment
Sealing Cop/Drag assembly
Joint Sealing / pasting / precuring
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DEWAXing Chamber / PitsWet Dewaxing InHOT Molten waxpit Dewaxing by Super sature.SteamDry dewaxing by soaking the tree in inverted position and thus cavity formed.Melted Wax is drained away.
Dewaxed Shell hollow from Inside and Ready for Firing /Curing.
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Hot metal metallurgical Charge Under preparation. . . . . .
Ferrous Metal charges for required alloying elements+Oxidiser
Control Metallurgy-Spectroanalysis Awaiting Tapping signal from chargman / Metallurgist
FIRING of SHELL
Dewaxed shell at 810*C
Residual wax to burnt Glasswool protection Reinforcing application Soak-time~Shell Volume Fragile Handling of Shell Shell Pouring BED Deoxidiser Masking of Shell
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Shell-bed & Pouring810*C fired shell on sand bed Proper seat on bed to absorb metal dropping while Metal Pour Crucible metal to hot fired shell ,Prevent shell puncturing Prevent Oxidation by Flux , Atmospheric Shied by Covering poured shell with help of blind drum with deadweight on top.
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Spark Spectro Analyzer
Deoxidizer
Shielding Shell Pouring
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Mr Bhatti & Mr Grossi on Shop visit Casting inspection / heat-treatment warp & Torn casting.
COINING Operation for Premium Casting
Restoring Dimension Loss in HT
Restoring Geometry Loss in HT
Restoring Size & Shape loss in Handling
.
Induction HardeningAutomotive Industrial products like Gearbox forks tips at 58/60 Rc
Special holding Fixture for com’t
Specially shaped HF Induction coil for every component.
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Induction Furnace Bay
500,250,100, 50 Kilograms
High frequency Induction furnace
Casted components for Heat TreatmentsAnnealing solution annealing Water Quenching Pack Carburizing Case Hardening Normalizing
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Shell Breaking hammers & Tree Cutting
Fused ceramic of shell are braked off by pneumatic hammers
Components are separated from cluster/tree by Gas cutter , Sawing ,
Plasma cutter,Diamond Cutters. Hollow Comp’t Internal passages are cleaned by Leaching, Hot NaOH solution for 48 Hrs
Dissolving SilicaHollow Components like ImpellersMr Grossi Verifying Any Fins, Blockage and Obstructions in the Impeller Vane Cavity.Core Lift/Core Breakage, Ballooningrestricting the Hydraulic passages & performance Challenging obstruction & defects.Strictly not AcceptableMetal lumps/fins/obstruction to be removed by Specially designed Curved Tooling & grinder - access remove any irregularities of the passages.Special tooling For Vane Obstruction Removal
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Core printCentral corelock
Corelocater
SucDia
Inlet tip Radii 1.5 mm
Perifaral core lock
Pressureside vane
Suctionside Vane
Impeller Cavity
Soluble Core Segment Perameter
Exit tip
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Impellers Under Metal Cleaning ProcessShot Blasting Steel / SSSand BlastingAcid CleaningHot NaOH LeachingWire BrushingStretch Filing & fit-ups
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Final Designing final Quality Control measures of componentsPre-Tooling Inspection Cad /Cam/tool Insp/Tool assly Insp/wax pattern trialDimensional Inspection confirming Drawing requirements + Geometrical tolePhysical Testing UTS/YP/YS/I Impact test/HardnessMetallurgical Requirements as per customer’s standards/Microscopic exam ’nNon Destructive testing DP,UT,MPT,RT, VI & Compliance of APIHydraulic Testing of Pressure tight ComponentsCommercial Verification Weight Analysis and S Q C Control
Ascertaining Convention Quality Check
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Impeller 100% Machining all Over with Six Axis Machining CenterVane Inlet Tip thickness 1.5mm and Bottom Raddi if 1.5mm
Impeller Rotating Speed 20Krpm to 70KrpmRotor assembly-Salvation & Restoration, Rework Dynamic Balancing
And Restoring to design functionality of High Speed turbo machines
With forecasted Capacity or Energy LossAs Interim FIX.
3D ModellingCAD / CAMProgramming3- Axis5-AxisMarching
NDT ComplianceAPI ComplianceOver speed TestBursting Test
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5 & 6 Axis Machining of Guide Vane and DiffuserMachining Accurany 25 Micron
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Trauma Engineering Services.,
Director
Mr Harshukh Bhatti,
Cell +919376195923 / +919429199089
[email protected] / [email protected]
A-51, Agrasen Towers, Opp:- BJ Medical College,
Camp Road, Ahmedabad, Gujarat-INDIA-380016