Cargando…
Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting
Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase too...
Autores principales: | , , , , |
---|---|
Formato: | Online Artículo Texto |
Lenguaje: | English |
Publicado: |
Mary Ann Liebert, Inc., publishers
2023
|
Materias: | |
Acceso en línea: | https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440664/ https://www.ncbi.nlm.nih.gov/pubmed/37609579 http://dx.doi.org/10.1089/3dp.2022.0225 |
_version_ | 1785093205404942336 |
---|---|
author | Andronov, Vladislav Beránek, Libor Zajíc, Jan Šotka, Pavel Bock, Martin |
author_facet | Andronov, Vladislav Beránek, Libor Zajíc, Jan Šotka, Pavel Bock, Martin |
author_sort | Andronov, Vladislav |
collection | PubMed |
description | Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (∼270 × 270 × 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the ŠKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in ŠKODA AUTO production also decreased. |
format | Online Article Text |
id | pubmed-10440664 |
institution | National Center for Biotechnology Information |
language | English |
publishDate | 2023 |
publisher | Mary Ann Liebert, Inc., publishers |
record_format | MEDLINE/PubMed |
spelling | pubmed-104406642023-08-22 Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting Andronov, Vladislav Beránek, Libor Zajíc, Jan Šotka, Pavel Bock, Martin 3D Print Addit Manuf Original Articles Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (∼270 × 270 × 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the ŠKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in ŠKODA AUTO production also decreased. Mary Ann Liebert, Inc., publishers 2023-08-01 2023-08-09 /pmc/articles/PMC10440664/ /pubmed/37609579 http://dx.doi.org/10.1089/3dp.2022.0225 Text en © Vladislav Andronov et al 2023; Published by Mary Ann Liebert, Inc. https://creativecommons.org/licenses/by-nc/4.0/This Open Access article is distributed under the terms of the Creative Commons Attribution Noncommercial License [CC-BY-NC] (http://creativecommons.org/licenses/by-nc/4.0/ (https://creativecommons.org/licenses/by-nc/4.0/) ) which permits any noncommercial use, distribution, and reproduction in any medium, provided the original author(s) and the source are cited. |
spellingShingle | Original Articles Andronov, Vladislav Beránek, Libor Zajíc, Jan Šotka, Pavel Bock, Martin Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting |
title | Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting |
title_full | Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting |
title_fullStr | Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting |
title_full_unstemmed | Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting |
title_short | Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting |
title_sort | case study of large three-dimensional-printed slider with conformal cooling for high-pressure die casting |
topic | Original Articles |
url | https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10440664/ https://www.ncbi.nlm.nih.gov/pubmed/37609579 http://dx.doi.org/10.1089/3dp.2022.0225 |
work_keys_str_mv | AT andronovvladislav casestudyoflargethreedimensionalprintedsliderwithconformalcoolingforhighpressurediecasting AT beraneklibor casestudyoflargethreedimensionalprintedsliderwithconformalcoolingforhighpressurediecasting AT zajicjan casestudyoflargethreedimensionalprintedsliderwithconformalcoolingforhighpressurediecasting AT sotkapavel casestudyoflargethreedimensionalprintedsliderwithconformalcoolingforhighpressurediecasting AT bockmartin casestudyoflargethreedimensionalprintedsliderwithconformalcoolingforhighpressurediecasting |