Study of the infill ratios effect on mechanica properties and ability to create a mold shell of casst able wax in 3d printing technology for investment casting

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 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.E 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.E Ho Chi Minh City, September 2023 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness GRADUATION PROJECT ASSIGNMENT Semester 2/ 2023 Advisor: M.E 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 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 Initial materials provided by the advisor: - Castable Wax resin - Formlabs Form printer - Surface roughness tester - Test tensile testing machine 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 Start Date: 15/03/2023 End Date: 22/07/2023 i 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.hcmute.edu.vn 19144085@student.hcmute.edu.vn 18144042@student.hcmute.edu.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.D.; Dang Minh Phung; Ph.D., Tran Minh The Uyen, Ph.D 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 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 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 trải qua phát triển tiến liên tục, tích hợp ngun tắc khoa học, cơng nghệ để nâng cao chất lượng sản phẩm quy trình sản xuất Bên cạnh đó, in 3D cơng nghệ đầy hứa hẹn, mở thêm nhiều hướng nghiên cứu phát triển tương lai Trong nghiên cứu này, công nghệ in 3D sử dụng để tạo vỏ khuôn dùng để đúc mẫu quy trình đúc mẫu chảy Tuy nhiên, số mẫu in 3D in đặc bên (mật độ điền đầy 100%) Đây hội để khám phá hướng nghiên cứu cách sử dụng tỷ lệ lấp đầy khác để tiết kiệm vật liệu tối ưu hóa quy trình tạo mẫu Trong luận văn này, thí nghiệm thực với tỷ lệ mật độ điền đầy khác nhau, dao động từ 5% đến 100% Các kết sử dụng để đánh giá tác động tỷ lệ infill khối lượng kích thước mẫu in, khả tạo vỏ khuôn chúng quy trình đúc mẫu chảy Qua đó, chúng tơi sử dụng kết thí nghiệm để nghiên cứu mẫu in có ảnh hưởng đến kích thước bề mặt mẫu đúc hay không Chúng xem xét nhiệt độ gia nhiệt vỏ khn ảnh hưởng đến kích thước đặc điểm bề mặt Ngoài ra, kiểm tra cấu trúc tế vi mẫu đúc kính hiển vi thực để đánh giá ảnh hưởng nhiệt độ gia nhiệt vỏ khuôn đến mẫu đúc Công nghệ Stereolithography (SLA) sử dụng để tạo mẫu in nhằm đánh giá mức độ ảnh hưởng tỷ lệ thấm khác đến tính chất học vật liệu Castable Wax, theo tiêu chuẩn ASTM D638 loại IV với tỷ lệ mật độ điền đầy khác Sự kết hợp in 3D đúc mẫu chảy mang đến hội để khám phá khả nâng cao chất lượng suất quy trình đúc mẫu chảy Những nghiên cứu thực đề tài góp phần nâng cao kiến thức mở rộng kiến thức mối quan hệ thông số in 3D, tỷ lệ mật độ điền đầy tính chất học vật liệu Castable Wax Những phát đóng vai trị hỗ trợ việc tối ưu hóa quy trình đúc mẫu chảy ngành cơng nghiệp iv TABLE OF CONTENTS GRADUATION PROJECT ASSIGNMENT i DISCLAIMER ii ACKNOWLEDGEMENTS iii ABSTRACT iv TABLE OF CONTENTS v LIST OF TABLES viii LIST OF FIGURES ix LIST OF KEYWORDS x LIST OF FORMULAS xi CHAPTER 1: INTRODUCTION 1.1 General introduction of investment casting and 3D printing technology 1.2 Objective 1.3 Research limitations 1.4 Research methods 1.4.1 Research methods 1.4.2 Available documents CHAPTER 2: THEORETICAL BASIS 2.1 Investment casting 2.1.1 Introduction 2.1.2 Process 2.1.3 Defects of investment casting 2.1.4 Advantages and disadvantages 2.2 Three-dimensional printing technology 10 2.2.1 Introduction 10 2.2.2 General process and classification 12 2.2.3 Stereolithography (SLA) 15 2.2.4 Application of SLA based 3D printing in investment casting 17 2.2.3 Introduction about “infill” 19 CHAPTER 3: MATERIALS AND METHODS 22 v