Feature Article
Yes, You Can Manage Your Tooling More Efficiently by Patrick McCrevan, Senior Account Executive, B&L Information Systems
or many years now, the mainstay usage of tooling in Investment Casting processes was primarily the mold used to make the wax components. These components are used to form the ceramic shell into which metal is poured for part creation. However, 3D printing processes have advanced to the point where the wax components can be formed by 3D printers, and further advancements have led to the ceramic shells themselves being formed by 3D printers. These things you already know. However, do you know how they fit into the overall cost of your product making process? Do you know how to maintain these processes, as a failure in them can cause big delays?
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In a classic lost wax investment process, tooling appears in multiple places. It can be specific to the part or specific to the process step, as shown below: 1. Pattern Creation: The first step in investment casting is to create an
accurate wax pattern of the desired part. Tooling in this context refers to the molds, dies, or patterns used to form the wax replicas. These tools are typically made from materials like aluminum or silicone and are designed to be highly precise and repeatable to ensure that each wax pattern is consistent.
2. Assembly: Depending on the complexity of the part, multiple wax
patterns may be produced
and assembled to form a cluster or tree. Tooling aids in the assembly process, ensuring that the patterns are correctly positioned and secured to create the final assembly.
3. Shell Mold Creation: The assembled wax patterns are then dipped in a ceramic slurry to create a shell mold. Tooling includes the fixtures used to submerge the tree.
4. Wax Removal: Once the ceramic shell is dry and hardened, it needs to be prepared for the casting process. Tooling is used in the wax removal step, where the entire assembly is heated, causing the wax to melt and drain out of the ceramic shell. Special ovens and tooling are used to control the heating process.
5. Preheating: Tooling is also employed to preheat the ceramic shells to the appropriate temperature to ensure a smooth and consistent metal pour.
6. Pouring and Casting: During the pouring phase, the ceramic shells are placed in a flask, and molten metal is poured into the shells. The tooling here includes the crucibles, ladles, and pouring equipment used to control the flow of molten metal.
7. Cooling and Solidification: After casting, the molds are allowed to
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