Metalcasting Industry Roadmap
The Metalcasting Industry Roadmap Process
Many needs have
manufacture metalcastings. These manufacturing, research,
been identified to more efficiently include rapid tooling development,
technology
advancements and integration of digital data threads, as well as transformative and potentially disruptive approaches to how cast metal components are produced. Process R&D can improve quality, enhance performance, reduce weight, reduce lead times, and improve the cost-effectiveness of cast parts. In developing a metalcasting roadmap to address the area of manufacturing process, the roadmapping development workshop participants identified eight major categories in which to group the new technologies and processes needed for metalcasting. The eight major categories are:
1. Additive Manufacturing and Rapid Subtractive Manufacturing in Metalcasting ± Additive Manufacturing (AM), such as 3D printing, is a process of making a three- dimensional solid object of virtually any shape from a digital model. 3D printing is achieved using additive processes, where successive layers of material are laid down in different shapes. 3D printing is also considered distinct from traditional machining techniques, which mostly rely on the removal of material by methods such as cutting or drilling (subtractive processes). Rapid Subtractive Manufacturing (RSM) involves the advancement of computerized numerical control (CNC), chemical material removal, other removal techniques, and integration of digital technology to create tools, patterns, and even molds quickly.
2. Lightweighting ± This refers to the need to reduce the weight and overall footprint of components in applications where castings are used. This is especially critical in the transportation sector (automotive, transport, aerospace) and defense / military products.
3. Smart Machines and Manufacturing ± This involves the integration of network-based solutions to collect data, manage that information, make critical decisions, and adopt and control processes to improve quality and efficiency.
4. Digital Thread Integration and Implementation ± This is the transformation of manufacturLQJ E\ GLJLWDO GHVLJQ ZKLFK UHSODFHV WKH GUDIWVPDQ¶V WDEOH ZLWK WKH FDSDFLW\ WR work and create in a virtual environment. A common digital and sharable format is used to enable transfer of design, modeling, process simulation, and manufacturing data and inspection information management. This creates a digital thread that leads to improved designs and more
efficient manufacturing processes to move beyond discrete
manufacturing operations, integrate the information, and disseminate it across broad shared networks.
5. Automation, Robotics, Ergonomics, and Sustainability ± These are used to improve the metalcasting work environment so it will not be as hot, dirty, or noisy and DOVR ZRQ¶W
23 Process
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