FPIC June 2, 2017 Terry Senish Director of Technology Application

Transcription

1 How to use advanced software and 3D Printing to create high quality castings for the Fluid Power industry FPIC June 2, 2017 Terry Senish Director of Technology Application Copyright 2016 The ExOne Company

2 Company Overview

3 Additive Manufacturing Technologies

4 Fluid Power- Typical sand cast components Pump components Compressor components Impellers Valve bodies/spools Hydraulic & Pneumatic valves Cylinder Housings Large castings Complex castings

5 Cast alloys used in the fluid power industry Carbon & Low Austenitic Martensitic Nickel Base Cobalt Base Brass & Bronze Tool Steel P-H Stainless Aluminum Alloy Stainless Stainless Alloys Alloys Cobalt 3 (Stellite 319 (SAE C836 ( , B62, SAE 1018 (WCC) A (CF16 Fa) 410 (5350G) Hastelloy B (N7M) 3) 326) 115, Leaded Red Brass) 1020 (WCC) A (CB7CU) 304 (CF8) 416 (5394B) 1025 (WCB) D (CD 4) 310 (CK20) 420F (CA40F) 1030 D-7 316L (CF3M) 431 (5353B) Hastelloy C (CW2M) Inconel 600 (CY40) Inconel 625 (CW6MC) 1040 H (CF8M) 440C (5352C) Incoloy M (CF8C) 440F (5362) Monel A 1050 M-4 Alloy 20 (CN7M) 442 (CB-30) Monel E 1141 O-1 Carpenter 20 CB3 CZ O-6 Nitronic S-7 HP (ASTM A297) 4150 T Cobalt 6 (Stellite 6) Cobalt 12 (Stellite 12) 356 (SAE 323, 326) 357 (SAE 357) 535 Almag 713 Tenzaloy C862 (SAE 423, High Strength Yellow Brass, 90,000 Tensile Manganese Bronze) C863 (SAE 424, High Strength Yellow Brass, 110,000 Tensile Manganese Bronze) C865 (SAE 421, High Strength Yellow Brass, 65,000 Tensile Manganese Bronze) C873 (Everdure, 4951, Silicon Bronze) C875 (SAE 500, SAE 64, 13B, Silicon Brass) C905 ( , Tin Bronze, Gun Metal) C907 (89-11, SAE 65, Tin Bronze) C922 ( , Leaded Tin Bronze) C952 (85-3-9, SAE 415A, #18, Aluminum Bronze 9A) C954 ( , SAE 415C, Aluminum Bronze 9D) Federalloy (I-848A, Nonleaded Brass) Beryllium Copper (ASTM B196 C17200) All capable of being cast using 3D Printed molds & cores

6 Fluid Power- Typical foundry issues / 3DP solutions Problems/Issues Patterns req. time/cost Zero or Negative Draft Core assembly, time Core parting lines, flash Core shift, scrap Re-Designs Gas, core venting Thin walls High complexity Chills Surface defects, veining Accuracy issues Mold assembly issues 3DP Advantages and Solutions 100% Patternless- quick lead time Lighter castings, quick mold design Quick assembly, reduced labor Single pc, no flash, no shift, better balance Simultaneous versions /quick revisions Low LOI, 3D venting capability Unique gating implementation Complexity is ~free 3DP chill molds Sand or additive additions Near net casting

7 Improved design and engineering software Tools CAD systems -Catia -Siemens NX -PTC Creo -SolidWorks -Solid Edge -Autodesk AutoCAD Analysis systems -Novacast- NovaFlow&Solid -Magmasoft Magma5 -ESI ProCast -EKK Altair

8 Learn to trust your software tools Software calibration, validation and testing Macro/Micro shrinkage predictions vs. actual, CT & RT Adjust s/w for both alloy and sand type

9 Software calibration, validation and testing Macro shrinkage predictions vs. actual cut up

10 Macro shrinkage Micro shrinkage Metal velocities Turbulence Residual stress analysis Per alloy chemistry Fill time Solidification time Temperature profile Pouring temp and min/max ranges Software Implementation Solidification modeling and analysis

11 Software Implementation Casting Orientation Choose the least of two evils with Natural Solidification

12 Improved surface finish -sand and binder technology

13 Improved surface finish -Additives Foundries use a variety of additives for various reasons. Additives that are currently available from ExOne are: Mg Inhibitor (Potassium Tetraflouroborate) *Veinseal *Black Iron Oxide *Zircon (10%) * - Currently only available through ExOne PSC

14 Improved surface finish Sand type Layer thickness Mold wash Flow rate Metal turbulence vs. tranquil fill

15 Improved Surface finish- Mold Wash Flow coat Brush coat Spray coat Zircon, Graphite Alcohol base Water base

16 Fluid Power Centrifugal casting RPM Grey Iron 1390 C 1430 C Up to 60G force High Strength High Soundness

17 Improved accuracy -Non traditional orientations and complex cores Blind risers for efficient feeding 1pc Vented & undercut core Alignment locators for high dimensional accuracy Copyright 2012 ExOne

18 Cost Reduction -Fluid power software/3d printing design benefits 3 cores reduced to a 1pc assy. 70% scrap reduced to <1% Less assembly time Less flash Less cleaning time Better quality Less overall cost $$

19 Silica Sand 3D Printed Cores

20 Case Study -Speed 3D Mold, 2535lbs/1150Kg. 7 Days Reduction

21 Castings Made From Silica Molds/Cores

22 Volute Geometry To Bigger Job Box X = 70 in. Y = 39 in. Z = 27 in Copyright 2012 ExOne

23 Large Segmented Cores and Molds

24 Typical Mold Assembly -cylinder housing

25 25 Copyright 2012 ExOne

26 26 Copyright 2012 ExOne

27 27 Copyright 2012 ExOne

28 Two Piece 70 inch Diameter Core Copyright 2012 ExOne

29 29 Copyright 2012 ExOne 29

30 ExOne The Americas MID-ATLANTIC 127 Industry Boulevard North Huntingdon, PA USA MIDWEST 2341 Alger Drive Troy, MI USA SOUTH 7409 Railhead Lane Houston, TX USA ExOne Europe ExOne GmbH Daimlerstrasse Gersthofen Germany ExOne Asia ExOne KK Haneo Odawara-shi, Kanagawa Japan Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.