MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT ELECTRONICS AND TELECOMMUNICATIONS ENGINEERING TECHNOLOGY STUDY OF THE INFILL RATIO’S EFFECT ON MECHANICAL PROPERTIES AND ABILITY TO CREATE A MOLD SHELL OF CASTABLE WAX IN 3D PRINTING TECHNOLOGY FOR INVESTMENT CASTING LECTURER: NGUYEN THANH TAN STUDENT: NGUYEN THANH PHUC NGUYEN VAN KHIEM HO THI YEN NHI S K L 01 0 8 4 4 Ho Chi Minh City, 2022 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING 🙡🕮🙣 GRADUATION PROJECT STUDY OF THE INFILL RATIO’S EFFECT ON MECHANICAL PROPERTIES AND ABILITY TO CREATE A MOLD SHELL OF CASTABLE WAX IN 3D PRINTING TECHNOLOGY FOR INVESTMENT CASTING Student name: Student ID: NGUYEN THANH PHUC 19144083 NGUYEN VAN KHIEM 19144085 HO THI YEN NHI 18144042 Major: MECHANICAL ENGINEERING TECHNOLOGY Advisor: NGUYEN THANH TAN, M. Ho Chi Minh City, September 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING 🙡🕮🙣 GRADUATION PROJECT STUDY OF THE INFILL RATIO’S EFFECT ON MECHANICAL PROPERTIES AND ABILITY TO CREATE A MOLD SHELL OF CASTABLE WAX IN 3D PRINTING TECHNOLOGY FOR INVESTMENT CASTING Student name: Student ID: NGUYEN THANH PHUC 19144083 NGUYEN VAN KHIEM 19144085 HO THI YEN NHI 18144042 Major: MECHANICAL ENGINEERING TECHNOLOGY Advisor: NGUYEN THANH TAN, M. Ho Chi Minh City, September 2023 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- GRADUATION PROJECT ASSIGNMENT Semester 2/ 2023 Advisor: M. Nguyen Thanh Tan Student name: Nguyen Thanh Phuc ID: 19144083 Phone number: 0981103143 Student name: Nguyen Văn Khiem ID: 19144085 Phone number: 0792095001 Student name: Ho Thi Yen Nhi ID: 18144042 Phone number: 0971962786 1.
ID of Project: 22223DT81 Project title: Study of the infill ratio’s effect on mechanical properties and ability to create a mold shell of Castable Wax in 3D printing technology for investment casting 2. Initial materials provided by the advisor: - Castable Wax resin - Formlabs Form 3 printer - Surface roughness tester - Test tensile testing machine 3. Main contents: - Overview 3D printing technology - Overview investment casting - Material in SLA 3D printing technology - Study the effect of the structure of 3D patterns on mold-making ability, dimension, and roughness of 3D printed and casted parts. Final product: - The report - Experiment result 5.
Languages: Report: English Vietnamese Presentation: English Vietnamese HEAD OF DEPARTMENT ADVISOR Graduation thesis defense ……………………………. i DISCLAIMER - Topic title: Study of the infill ratio’s effect on mechanical properties and ability to create a mold shell of Castable Wax in 3D printing technology for investment casting - Instructor: M.E Nguyen Thanh Tan - Members: Nguyen Thanh Phuc ID: 19144083 Phone: 0981103143 Nguyen Van Khiem ID: 19144085 Phone: 0792095001 Ho Thi Yen Nhi ID: 18144042 Phone: 0971962786 - Email: 19144083@student.vn We declare that this graduation thesis is the result of our research and work. We have not copied any published articles without proper citation. If any violation is found, we take full responsibility for it.
Ho Chi Minh City, September 2023 ii ACKNOWLEDGEMENTS This graduation project has been completed with the support of various resources. We would like to express our gratitude to everyone who contributed to this project, whether directly or indirectly. Prima facie, heartfelt appreciation is expressed to Ho Chi Minh City University of Technology and Education, particularly the Faculty of High-Quality Training, and the Faculty of Mechanical Engineering. Their dedication to creating an exceptional learning environment and providing valuable tools and resources has greatly enriched our academic and practical experiences.
Secondly, we take this opportunity to thank all the faculty members of the Department for their assistance and support. The knowledge imparted by these esteemed educators is the most valuable asset we carry with us upon graduation. Furthermore, the solid fundamental they have provided has significantly contributed to the successful completion of this project. Thirdly, we could not have undertaken this journey without M.E Nguyen Thanh Tan, our instructor.
We are very grateful for the guidance, support and sharing of his expertise and fund, these things have contributed to helping us complete the graduation project effectively. Moreover, his provision of ideal working conditions throughout the project development process has been invaluable. Additionally, we would like to express our sincere gratitude to Tran Van Tron, Ph.; Dang Minh Phung; Ph., Tran Minh The Uyen, Ph. and others for their support in providing background knowledge and laboratory equipment.
Thanks to their advice, the implementation process of our topic was enhanced and improved. Special thanks are also given to Dong Luc and 3D Smart Solutions Company for generously providing all the necessary facilities for our research. The company has given us an overview and specific details about the process of making a product using the investment casting technique, allowing us to further enhance our research for this project. Finally, we are sincerely thankful for the support and companionship from family and friends, who are a major distribution to the project.
The project will have limitations and errors in the implementation due to lack of time and practical experience. Thank you very much if you have any advice or suggestions for the project to be more complete. Good health and success in your careers are wished for. Thank you for being a part of our journey.
iii ABSTRACT Currently, the field of investment casting is experiencing continuous growth and advancement, integrating sophisticated scientific and technological principles to elevate product quality and streamline manufacturing processes. 3D printing, as a promising technology, opens up numerous avenues for research and development in the future. In this study, 3D printing technology was utilized to create investment casting patterns. However, some 3D printed patterns are solid inside (100% infill).
This presents an opportunity to explore new directions by using various infill ratios to conserve materials and optimize the pattern creation process. In this thesis, experiments were conducted with 8 different infill ratios, ranging from 5% to 100%. The results were used to assess the impact of infill ratios on the weight and dimensions of the printed patterns, as well as their mold shell formation capabilities. Consequently, we used the outcomes of these experiments to study how printed patterns affect the dimension and surface of the casted patterns.
We also looked at how the heating temperature affects these dimensions and surface characteristics. Additionally, microscopic examinations were performed to evaluate the influence of heating temperature on the microstructure of the casted patterns. Moreover, Stereolithography (SLA) technology was employed to create printed parts to assess how different infill ratios affect the mechanical properties of the Castable Wax material according to ASTM D638 type IV with 8 different infill ratios. The combination of 3D printing and investment casting presents an exciting opportunity to explore new possibilities and enhance the overall quality and efficiency of the casting process.
The research conducted in this study contributes to advancing the knowledge and understanding of the interactions between 3D printing parameters, infill ratios, and the mechanical properties of Castable Wax. These findings serve as valuable support in optimizing investment casting processes within the industry. iv TÓM TẮT Ngày nay, lĩnh vực đúc mẫu chảy đang trải qua sự phát triển và tiến bộ liên tục, tích hợp các nguyên tắc khoa học, công nghệ để nâng cao chất lượng sản phẩm và quy trình sản xuất. Bên cạnh đó, in 3D là một công nghệ đầy hứa hẹn, sẽ mở ra thêm nhiều hướng nghiên cứu và phát triển trong tương lai.
Trong nghiên cứu này, công nghệ in 3D được sử dụng để tạo ra các vỏ khuôn dùng để đúc mẫu trong quy trình đúc mẫu chảy. Tuy nhiên, hiện tại một số mẫu in 3D được in đặc bên trong (mật độ điền đầy 100%). Đây là cơ hội để khám phá một hướng nghiên cứu mới bằng cách sử dụng các tỷ lệ lấp đầy khác nhau để tiết kiệm vật liệu và tối ưu hóa quy trình tạo mẫu. Trong luận văn này, các thí nghiệm được thực hiện với 8 tỷ lệ mật độ điền đầy khác nhau, dao động từ 5% đến 100%.
Các kết quả được sử dụng để đánh giá tác động của tỷ lệ infill đối với khối lượng và kích thước của các mẫu in, cũng như khả năng tạo vỏ khuôn của chúng trong quy trình đúc mẫu chảy. Qua đó, chúng tôi đã sử dụng kết quả của những thí nghiệm này để nghiên cứu các mẫu in có ảnh hưởng đến kích thước và bề mặt của các mẫu đúc hay không. Chúng tôi cũng xem xét nhiệt độ gia nhiệt vỏ khuôn ảnh hưởng đến các kích thước và đặc điểm bề mặt. Ngoài ra, kiểm tra cấu trúc tế vi của các mẫu đúc bằng kính hiển vi được thực hiện để đánh giá ảnh hưởng của nhiệt độ gia nhiệt vỏ khuôn đến mẫu đúc.
Công nghệ Stereolithography (SLA) đã được sử dụng để tạo ra các mẫu in nhằm đánh giá mức độ ảnh hưởng của các tỷ lệ thấm khác nhau đến tính chất cơ học của vật liệu Castable Wax, theo tiêu chuẩn ASTM D638 loại IV với 8 tỷ lệ mật độ điền đầy khác nhau. Sự kết hợp giữa in 3D và đúc mẫu chảy mang đến một cơ hội để khám phá những khả năng mới và nâng cao chất lượng cũng như năng suất của quy trình đúc mẫu chảy. Những nghiên cứu được thực hiện trong đề tài này góp phần nâng cao kiến thức và mở rộng kiến thức về mối quan hệ giữa các thông số in 3D, tỷ lệ mật độ điền đầy và các tính chất cơ học của vật liệu Castable Wax. Những phát hiện này đóng vai trò hỗ trợ trong việc tối ưu hóa quy trình đúc mẫu chảy trong ngành công nghiệp hiện tại.
iv TABLE OF CONTENTS GRADUATION PROJECT ASSIGNMENT. iv TABLE OF CONTENTS. v LIST OF TABLES. viii LIST OF FIGURES.
ix LIST OF KEYWORDS. x LIST OF FORMULAS. xi CHAPTER 1: INTRODUCTION.1 General introduction of investment casting and 3D printing technology. 3 CHAPTER 2: THEORETICAL BASIS .3 Defects of investment casting .4 Advantages and disadvantages .2 Three-dimensional printing technology .2 General process and classification .4 Application of SLA based 3D printing in investment casting .3 Introduction about “infill”.
19 CHAPTER 3: MATERIALS AND METHODS .1 Castable wax resin .3 Evaluation Mechanical Properties .4 Surface roughness measurement .5 Metallography Specimen Preparation and Microscopic Examination .2 Preparation of shell mold. 34 CHAPTER 4: EXPERIMENT RESULTS AND DISCUSSION .1 Effect of infill ratio on the mass of 3D printed part .2 Effect of infill ratio on dimensional accuracy of 3D printed part.3 Effect of infill ratio on mechanical properties of Castable Wax material .4 Effect of infill ratio on the ability to create mold shell .5 Effect of temperature heating for the mold shell on the dimension of casted part .6 Effect of temperature heating for the mold shell on the surface roughness of casted part .7 Effect of temperature heating for the mold shell on the microstructures of casted part. 67 v LIST OF TABLES Table 4.1: The actual mass and nominal mass results of the printing part, in gram .2: The dimensional value is compared across different infill ratios.3: The different infill ratios are compared across dimensional values.4: The dimensional values are compared across different infill ratios.5: The dewaxing process by temperature with a density of 5% .6: The dewaxing process under the same time conditions of different infill ratio54 Table 4.7: The dimensional values are compared across different casting sample.8: The casting samples are compared across different dimensional values.9: The surface roughness of the 3D printed parts, in micrometers (µm).10: The surface roughness of the casted parts, in micrometers (µm).11: The mold temperature affects the microstructure of the sample.