PROTO ENGINEERING INVESTMENT CASTING dESIGN ENGINEERING(CoNTD) Provide design/detail drawing(2D)and solid model (3D) conversion as required for the following Dip brazing to casting Sheet metal to casting Weldment to casting Machined part"hog out"to casting Multi-piece assemblies(sheet metal or machined) to casting Provide engineering drawings per Y 14.5M-1982 or Y14.5M-1994 Assist in material and specification selection Recommend material specification, classification and method for determining mechanical properties, x-ray of designated areas(when required)and general processing notes based on system/component requirement Discuss/define advantages/disadvantages Provide the following Design/detail (2D& 3D)via CADKEY and or PRO E Systems/part analysis(FEA)via NASTRAN)
PROTO ENGINEERING I NVESTM ENT CASTING DESIGN & ENGINEERING (CONT’D): • Provide design/detail drawing (2D) and solid model (3D) conversion as required for t he following: • Provide engineering dra wings per Y14.5M - 1982 or Y14.5M - 1994. • Assist i n material and specification sel e ction: • R e c ommend mat erial spe cific ation, classification and method for determining me c hanic al properties, x-ray of designated areas (when required) and general processing notes based on syste m/component requirements. • Disc uss/de fine advantages/disadvantages. • Dip brazing to c asting. • S heet metal to c astin g. • Weldm ent t o casting. • Machine d part “hog out” to c asting. • M ultipiece assemblies (sheet metal or machin e d) to casting. • Design/det ail (2D & 3D) via CAD KEY and or P RO E. • S ystems/part a nalysis (FEA) via NASTRAN). • Provide the following:
PROTO ENGINEERING RAPID PROTOTYPING (WOOD PROCESS) Rapid prototyping process for investment castings unique to Proto Engineering and Nu-Cast Inc Pattern fabrication is via A/C plywood(computer generated or machined assembled parts)as compared with the use of computer generated resins(SLA). This process has been used for over 35 years and currently provides additional flexibility the use of investment castings for limited production or development runs Advantages over the SLa type process Design changes can be implemented at any time during pattern generation and even into the shell process extreme situations. This process in general allows for changes after pattern review Pattern/part size limited to foundry facility only(currently 80 inches in length ( Nu-Cast Inc) Solid model(CAD)not required (2D acceptable Fillet radii and outside radii not required in CAD file Minimal wall thickness 02/03 available(requires engineering or foundry review) No pattern shrinkage to contend with allowing for greater pattern tolerance control Proto Engineering Aerospace/Investment Casting Design and Rapid prototyping Gordon h. goodwin
PROTO ENGINEERING RAPID P ROTOTYPING ( WOOD P ROCES S): • R a pid prototyping process for investment c astings unique to Proto Engine ering and Nu-Cast Inc P attern fabrication is via A/C plywood (computer generated or m a c hined assembled parts) as com pared wit h the use of computer generated resins (SLA). This process has been used for over 35 years and currently provides additional flexibility in the use of investm ent c astings for limited production or developme nt runs. • Advantages over the S LA type proc ess: • Design changes c a n be imple ment ed at any time during pattern generation and eve n into the shell process in e xtreme situations. This process in general allows for c hanges after pattern revie w. • P attern/part size limited to foundry facility only (currently 80 inc hes in length @ Nu-Cast Inc). • Solid model (CAD) not required (2D accepta ble). • Fillet radii and outside radii not required in CAD file. • Mini mal w all t hickness .02/.03 available (requires engineering or foundry revie w). • No pattern shrinkage to contend with allowing for gre ater pattern tol eranc e control, Proto Engin e e ring Aer ospac e/Investme nt Casti ng Design and Rapid Prototyping Gor don H. Goodwin