Z Corporation Z 406 Uživatelský manuál

Z406 System User Manual September 2004 © 2003-2004 Z Corporation Part Number 09520 Z®406 3D Color Printer User Manual Z Corpora

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Appendix I 09521 ZCast® Design Guide Rev E ZCast® 501 Direct Metal Casting DESIGN GUIDE September 2004

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Appendix I ZCast Design Guide - 2 Table of Contents 1 Introduction...

Appendix I ZCast Design Guide - 3 Seal –...

Appendix I ZCast Design Guide - 4 1 Introduction The ZCast® process was created to allow for the rapid fabrication of metal parts. It allows cast met

Appendix I ZCast Design Guide - 5 2 General Safety This manual has safety information and instructions to help users reduce or eliminate the risk of

Appendix I ZCast Design Guide - 6 2.3 Safety Instructions Read and follow this safety information to reduce or eliminate the risk of accidents and pe

Appendix I ZCast Design Guide - 7 WARNING Inadequate venting in the mold or core can lead to the unexpected release of entrapped gases and molten met

Appendix I ZCast Design Guide - 8 PREPARING AND BAKING MOLDS WARNING Bake ZCast molds until all moisture is removed before metal casting. Residual m

Appendix I ZCast Design Guide - 9 FINISHING CAUTION Breaking molds with a hammer or high-pressure water jet releases airborne objects and may cause

Appendix I ZCast Design Guide - 10 3 ZCast Advantages Today, metal casting molds are commonly created by first producing a machined pattern (or patte

Appendix I ZCast Design Guide - 11 particularly useful for assembling large molds that are too large to fit in the build volume of the Z Corporation P

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Appendix I ZCast Design Guide - 12 4 Locating a Foundry Whether you are an experienced mold designer with a foundry in-house, or a design engineer w

Appendix I ZCast Design Guide - 13 5 Designing with ZCast – Mold Design ZCast powder offers flexibility and simplicity in mold design. Because of it

Appendix I ZCast Design Guide - 14 5.2 Selecting a Design Method This first step in designing a mold is to decide which design method best suits the

Appendix I ZCast Design Guide - 15 Figure 4: Shell Method – ZCast components of a shell mold (left). Assembled mold with ZCast components pa

Appendix I ZCast Design Guide - 16 5.3 Designing Molds in your CAD System Regardless of the method you select, it is likely that some CAD work w

Appendix I ZCast Design Guide - 17 9. Add mating features to help align the mold components. These can be simple holes pegged with dowel pins, or ma

Appendix I ZCast Design Guide - 18 5.3.3 Combination Method The combination method is slightly more process oriented and is not represented in the co

Appendix I ZCast Design Guide - 19 6 Design Techniques with ZCast Patterns 6.1 Direct Gating Conventional methods of runner design are based on havin

Appendix I ZCast Design Guide - 20 6.4 Stiffening Ribs Increase the strength of your mold with the addition of stiffening ribs. You can use the Make

Appendix I ZCast Design Guide - 21 into the metal. When gas passes through the metal as it cools, it can be trapped, forming pockets called porosity.

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Appendix I ZCast Design Guide - 22 6.5.2 Venting the Mold Vented molds facilitate the safe passage of gas generated as a result of molten metal comin

Appendix I ZCast Design Guide - 23 Suggested Solutions: • For the majority of the molds, there should be least a 0.5 in (13 mm) wall thickness betwe

Appendix I ZCast Design Guide - 24  Make sure that geometries are properly shelled. Almost all molds are capable of having ‘sacrificial’ outer surfa

Appendix I ZCast Design Guide - 25  Creating a runner bar, for example, across the heat sink fins would help to facilitate proper filling; however m

Appendix I ZCast Design Guide - 26 Figure 10: Attach a flexible plastic hose like the one shown above to reach ‘blind spots’ CAUTION Parting lines n

Appendix I ZCast Design Guide - 27 radius to the bottom edges of core prints where they sit in the cope or drag; this provides space for loose powder

Appendix I ZCast Design Guide - 28 6.11 Pouring Sleeves & Risers A pouring sleeve is a tapered cylinder made of a refractory material with a cera

Appendix I ZCast Design Guide - 29 • For mating parts (such as a cope and drag of the same mold), try to always print them in the same orientation i

Appendix I ZCast Design Guide - 30 Figure 13: a,b,c: Horizontal filter orientation – Metal rises up through filters (maximum are achieved with horizo

Appendix I ZCast Design Guide - 31 7 Mold Preparation After the mold is designed and printed in a Z Corp. 3D Printer, there are only a few necessary

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Appendix I ZCast Design Guide - 32 Clamp – Carefully close the mold with the cores in place. Clamp with C – clamps or similar and orient in the prop

Appendix I ZCast Design Guide - 33 8 Pouring Metal 8.1 Metal Types The current product offering is ZCast 501 powder and is designed for low temperatu

Appendix I ZCast Design Guide - 34 9 Material Handling 9.1 Storage Though ZCast powder has no special storage requirements; it should be stored in a

Appendix I ZCast Design Guide - 35 10 Finishing 10.1 De-molding Removing a casting from a ZCast mold is virtually identical in process to the removal

Appendix I ZCast Design Guide - 36 11 Foundry Consumables You can purchase foundry consumables through a wide offering of vendors. This includes items

Appendix I ZCast Design Guide - 37 11.1 Sand Casting Glossary 11.1.1 Cope and Drag Molds are typically made up of two halves encapsulating the outer

Appendix I ZCast Design Guide - 38 11.1.4 Pouring Cup The pouring cup, as the name implies, is where the molten metal is poured into the mold. The p

Appendix I ZCast Design Guide - 39 11.1.8 Ingates The metal enters the mold cavity through the ingates. Ingates typically feed thicker sections of th

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