Modern process planning for additive manufacturing assisted a 356 aluminum casting

Abstract

Foundry engineering integrates mechanical design, thermal-fluid dynamics, and material science to cast components of a unique design. This project was intended to apply these concepts to optimize the casting process of an aircraft Bearing Housing by applying the design flexibility obtained from additive manufacturing (AM). The two AM processes that were studied include 3D sand printing and 3D wax printing to determine their advantages when applied to sand and investment casting, respectively. For efficiency, generative design (GD), computational fluid dynamic (CFD), and phase field (PF) simulation were used to rapidly compare the outcomes of multiple rigging systems prior to 3D printing molds. Once verifying the optimal design based on the part’s geometry, the mold prototypes were printed and casted in controlled laboratory conditions. The material properties were tested and characterized at critical cross sections to verify consistency of results to the simulated environments.