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Metal Casting Center to produce a piece, shown in Figure 5, which high- lights the complexity of 3-D printed parts while showing the limitations of sand removal from complex designs. Te traditional method of using


Fig. 5. The University of Northern Iowa’s art department designed a fairly complex component. initial solidification (Fig. 4).


Vent Placement Venting in 3-D designed molds is


a relatively simple process because the need to integrate vents into a hard tooling pattern is eliminated. Vents are created in the 3-D mold model, which allows for improved precision and efficient placement of the vents based upon the air entrapment and


air pressure results obtained from the filling simulation.


Unbonded Sand Removal & Parting Lines


While the main application for 3-D sand printers is industrial part production, this technology can be used to create new works of art. Dan Perry, a sculptor from Northern Iowa’s art department, collaborated with the


horizontal cutting planes proved to be insufficient for complete removal of uncured sand, which can lead to cast- ing defects. In this case, the residual sand had prevented the normal pas- sage of the molten metal, leading to a misrun defect in that particular area. A large amount of unremoved sand in the casting also can act as a local chill in certain areas, especially those with thinner sections. Tis misrun was due to insufficient cleaning techniques, which prevented the removal of loose sand after printing. Due to the complex nature of the


feather mold, traditional parting lines weren’t sufficient for proper sand removal. Surface contour offset parting lines were designed to allow complete access to the inside of the mold for sand removal. Te surface offset part-


START TO FINISH—FEF GRADUATES ARE PROMINENT PEOPLE IN THE INDUSTRY


From the First Time Pouring Metal at an FEF School to Now... • Division Sales Manager


• Engineering Manager • VP of Operations • Technical Services Manager


Leading... • Hundreds of employees • Multi-Million Dollar Projects • Company Strategies


Giving Back to the Industry... • FEF and AFS Board Members • Chapter Leadership • Local Community Charitable Initiatives


Contact FEF when you are looking for someone to “hit the ground running” or to make a donation!


Foundry Educational Foundation 1695 N. Penny Lane•Schaumburg, IL 60173•www.fefinc.org•847-490-9200


26 | MODERN CASTING May 2015


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