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Virtual commissioning of wax model gluing for investment casting
Maňák, Juraj ; Bražina, Jakub (referee) ; Szabari, Mikuláš (advisor)
The thesis deals with the virtual commissioning of a robotic workstation for gluing wax models for investment casting. The theoretical part describes the concept of Industry 4.0 and its main pillars, followed by the technology of investment casting and the entire process from wax mold to casting. The next part summarizes the knowledge of robot programming methods and virtual commissioning. This is followed by a chapter analyzing the current methods of gluing and describing the individual components of a universal workstation.The practical part begins with the design of the robotic workstation, including components such as positioners and grippers, and their subsequent description. The next part focuses on creating a simulation in the Process Simulate software, including the definition of kinematic structures and operations. The thesis also describes the process of virtual commissioning, the use of Robot Studio for real feedback, and the subsequent creation of PLC and HMI in TIA Portal.
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Virtual commissioning of automatic investment casting shell removal
Vach, Pavol ; Bražina, Jakub (referee) ; Szabari, Mikuláš (advisor)
The aim of the diploma thesis is to design and virtually commission a robotic workplace for the automatic removal of shells from castings for investment casting technology. The theoretical part summarizes an overview of programming of industrial robots, PLCs and software for virtual commissioning. Subsequently, the investment casting technology is described. In the analysis of problematics, there is a description of assigned components and analysis of methods for removing shells from castings with a focus on the automation of this process. This is followed by the design of the workplace layout, the virtual commissioning of its model, the design of the control and user interface.
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Production of a replica of the switch cover using the investment casting method
Klátil, Ondřej ; Kaněra, Miloš (referee) ; Jelínek, Radim (advisor)
The work is focused on the production of a replica switch cover for the ČZ 250/471 motorcycle from 1974. The theoretical part of thesis includes a review of the production of permanent and expendable patterns, mold making, various casting methods, additive technologies categorized under rapid prototyping methods, and a description of scanning methods. In the experimental part, the informations from the theoretical part are verified through the experiment of producing the switch cover replica. The original part was first scanned, then the scan was edited and converted into a solid model, which was then printed on an FDM printer as a expendable pattern for the investment casting method using shell molds. These castings were then evaluated against the originals. At the end of the experiment, surface defects were found, the causes of which could not be definitively explained. Subsequently, various production methods were outlined for specific ranges according to the number of products.
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Casting production of an optimized inlet shape of pneumobile engine pneumatic cylinder
Bouchner, Jan ; Záděra, Antonín (referee) ; Krutiš, Vladimír (advisor)
Presented bachelor's thesis deals with production of a pneumatic component using hybrid investment casting technology. This method combines investment casting with additive technologies. The manufactured component, called cap-end, supplies compressed air to the pneumatic drive of a racing car. Complex design of this component was created using computer fluid dynamics optimization. This design was delivered by the Pneumobile racing team Brno. Presented thesis further contains a technological consideration taking into account solidification direction, on the basis of which the delivered geometry was modified. Manufacturability of the component is verified by a numerical simulation in the ProCAST environment. This thesis also describes printing process of a combustible model using fused deposition modelling technology. The combustible model is used in the production of a ceramic shell. Using said ceramic shell AlSi10Mg alloy casting was made. The component had to meet the requirements for leak tightness after machining and subsequent assembly. The leak tightness is assessed here as a pressure drop in a closed circuit measured over time. Furthermore, the effect of the cap-end on properties of the racing car in relation to the original geometry was investigated. The comparison is made on the basis of the race car's unloaded wheel speed measurements. The outcome of the thesis is a functional cap-end component that validates the results of a scientific article published by members of the Pneumobile racing team Brno.
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The Influence of Cooling Rate on the Microstructure of Casting Produced by Investment Casting
Vybíral, Ondřej ; Kaňa, Václav (referee) ; Nekuda, Pavel (advisor)
The presented work provides an insight into the theme of investment casting method and the metallurgy of aluminum alloys, focusing on silumins and their crystallization. In the experimental part, three test castings were made from the AlSi7Mg alloy using this method, with combination of various cross-sections and different cooling rates. SDAS analysis was used to evaluate the influence of cooling rate on the microstructure. The measured values were examined for their dependencies on the cooling rate, casting cross-section, and different sampling locations. The measurements demonstrated that SDAS value is lower in castings with higher cooling rates and smaller cross-sections. At the same time, higher value was measured in samples taken near thermal nodes.
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Manufacture of Artistic Castings
Janošťák, Jan ; Staňková, Markéta (referee) ; Mikulka, Vít (advisor)
This bachelor’s thesis is focused on types of casting methods, which are or were used for the production of art objects. Chronological cross-section through history of art casting is made at first, which is followed by an analysis of the most common methods and techniques leading to the production of art castings. The following practical part of the bachelor’s thesis concerns itself with the production of a simple art casting. The lost-wax process was used for its fabrication.
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Use of 3D technology in foundry industry
Straka, Pavel ; Krutiš, Vladimír (referee) ; Pernica, Vítězslav (advisor)
The work is focused on replacing a faulty briefcase handle with an aluminium substitution. The handle is fabricated with the help of reverse engineering, where the handle is scanned with a 3D scanner. With that information, a model copy of the part is made, which is 3Dprinted from PLA and PolyCast materials. These handles are used as expendable models, which are used for casting using an “investment casting” method. Those are made from an AlSi10Mg alloy. Theoretical part deals with additive technologies, which are mostly used for manufacturing of foundry models and moulds. Next, the basic principles of 3Dscanning are described, and the term reverse engineering is also explained.
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Possibilities of using aditive technologies in direct manufacturing of foundry moulds
Herzán, Jiří ; Šlajs, Jan (referee) ; Horáček, Milan (advisor)
The bachelor thesis deals with the production of foundry molds with using additive technologies. At first, the additive technologies are distributed according to ASTM (American Society for Testing and Materials) and subsequently according to the state of the base material. Then, three types of technologies, that can be manufactured by Rapid Prototyping are described. The last chapter of the bachelor thesis is a real example of the production of a prototype fan casting from aluminum alloy AlSi9Cu3(Fe), which was casted into a printed mold by “3D Sand Printing” technology. Based on the obtained data were assessed technical, time and cost parameters of manufacturing the fan. The findings were compared with the molding technology of the ordinary printed pattern, which is an alternative to prototype production. The casting of the fan was cast in Armatmetal s.r.o. in Olomouc.
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Influence of Cyclone process parameters on the quality of ceramic shells
Lederer, Vojtěch ; Šustek, Petr (referee) ; Krutiš, Vladimír (advisor)
Diploma thesis contains introduction into shell drying, its monitoring and influence on shell properties. The thesis works with the Cyclone machine described further. The shell drying process in the machine and experiments are carried out broadening understanding of functions and parameters of rapid drying process. Experiments comparing courses of drying under respective settings of Cyclone and under common drying in air-conditioned room are carried out. Also mechanical properties of commonly dried shells and shells made by the Cyclone machines are compared. The positive effect of the machine on the ultimate strenght of dried shells and positive effect on the drying speed has been confirmed.
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