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Hybrid foundry patterns of bevel gears

Keywords: Innovative materials and casting technologies , Gears , Rapid prototyping systems , Stereolithography , Lost-wax casting method

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Possibilities of making hybrid foundry patterns of bevel gears for investment casting process are presented. Rapid prototyping of gears with complex tooth forms is possible with the use of modern methods. One of such methods is the stereo-lithography, where a pattern is obtained as a result of resin curing with laser beam. Patterns of that type are applicable in precision casting. Removing of stereo-lithographic pattern from foundry mould requires use of high temperatures. Resin burning would generate significant amounts of harmful gases. In case of a solid stereo-lithographic pattern, the pressure created during gas burning may cause the mould to crack. A gas volume reduction may be achieved by using patterns of honeycomb structure. However, this technique causes a significant worsening of accuracy of stereo-lithographic patterns in respect of their dimensions and shape. In cooperation with WSK PZL Rzeszów, the Machine Design Department of Rzeszow University of Technology carried out research on the design of hybrid stereo-lithographic patterns. Hybrid pattern consists of a section made by stereo-lithographic process and a section made of casting wax. The latter material is used for stereo-lithographic pattern filling and for mould gating system. The hybrid pattern process consists of two stages: wax melting and then the burn-out of stereolithographic pattern. Use of hybrid patterns reduces the costs of production of stereolithographic patterns. High dimensional accuracy remains preserved in this process.


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