Course detail

Additive Technologies in Foundries

FSI-PTS Acad. year: 2024/2025 Summer semester

The course introduces students to basic approaches to data processing for models produced by the rapid prototyping (RP) method. They acquire basic knowledge of RP principles, including an overview of additive manufacturing (AM) methods applicable in foundry technology. They gain hands-on experience using AM for prototyping. The subject includes hybrid technologies, computer support for the production of molds and models, including quality control methodology and the economics of producing prototype castings.

Supervisor

Ing. Vladimír Krutiš, Ph.D.

Department

Institute of Manufacturing Technology

Learning outcomes of the course unit

Prerequisites

Planned learning activities and teaching methods

Assesment methods and criteria linked to learning outcomes

Language of instruction

Czech

Aims

In this subject, students will get acquainted with the preparation and use of data needed for 3D scanning of models and castings, for numerical simulations and virtual engineering. Students will learn about the basic methods and principles of the RAPID PROTOTYPING (RP) technology, including reverse engineering procedures (RE). They will get familiar with the selected modern technologies for manufacturing castings and process management methods with the application of the industry 4.0 principles. They will also learn model surfacing and smoothing procedures and methods for RP, molds and castings and they will get acquainted with the dimension and shape accuracy testing methods and metallographic and phase casting material assessment methods. Part of the subject will also be to obtain knowledge of the composition of production costs and the foundry production economy.

 

Students will acquire the knowledge and skills of 3D modelling (designing and making), rapid prototyping methods (RP), using computer technology for 3D measuring (scanning), numerical simulations of foundry procedures etc. Process management in selected foundry technologies including quality control and composition and production cost management in prototype production.

Specification of controlled education, way of implementation and compensation for absences

The study programmes with the given course

Programme N-SLE-P: Foundry Technology, Master's
branch ---: no specialisation, 5 credits, compulsory

Programme C-AKR-P: , Lifelong learning
branch CLS: , 5 credits, elective

Type of course unit

 

Lecture

26 hours, optionally

Syllabus


  1. Foundry production – division of production technologies, technological nature of construction. Stress in castings – construction.

  2. Industry 4.0 – new technological challenges.

  3. CAD modeling – principles, methods and tools for creating 3D model drawings for RP methods and numerical simulation.

  4. Optimization of casting construction – topological optimization, generative design.

  5. Reverse engineering methods.

  6. Methods of 3D scanning and image processing.

  7. Additive technology – division, principles of individual methods.

  8. Additive production of foundry models.

  9. Additive production of metal materials.

  10. RP methods suitable for foundry practice, examples of use, achievable parameters.

  11. Surface treatment of models for RP, surface treatment of molds for selected modern technologies.

  12. Case studies, examples from practice.

  13. Economic aspects of prototyping using additive manufacturing.

Laboratory exercise

39 hours, compulsory

Syllabus

1. – 3. Making 3D casting models and patterns using Solid Works software.
4. – 5. Model preparation for 3D printing – slicer.
6. – 8. 3D printing of selected projects.
8. – 12. Ceramic shell making, prototype pouring
13. Quality control of castings, evaluation.