Research Papers

Use of Fused Deposition Modeling of Polyphenylsulfone for Centrifugal Casting of Polyurethane: Material, Surface, and Process Considerations

[+] Author and Article Information
Thomas Martens, Monty Graham

Laine Mears

International Center for Automotive Research,  Clemson University, 4 Research Drive, Greenville, SC 29607 mears@clemson.edu

Mike Dotson

Michelin Americas R&D Company, 515 Michelin Rd, Greenville, SC 29605michael.dotson@us.michelin.com

Phillip Sanger

 Western Carolina University, Department of Engineering and Technology, Cullowhee, NC 28723sanger@email.wcu.edu

J. Manuf. Sci. Eng 133(5), 051003 (Sep 22, 2011) (10 pages) doi:10.1115/1.4004848 History: Received June 26, 2011; Revised August 04, 2011; Published September 22, 2011; Online September 22, 2011

For the development of a rotational symmetrical polyurethane part with a steel reinforcement, a requirement/constraint driven approach to process design has been taken. In this approach a scale model of the casting mold was built using fused deposition modeling rapid prototyping technique, then used to validate design, material and process parameters. After selection and testing on the scaled prototype, results were used to define a full-sized spin casting mold built using polyphenylsulfone material. This material was selected based on the process temperature and stress requirements. However, surface roughness in the as-built condition is unacceptable for demolding; this paper describes secondary processing to mitigate this effect. The result is a feasible process for manufacturing of centrifugal casting molds for polyurethane.

Copyright © 2011 by American Society of Mechanical Engineers
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Figure 1

Selection sequence

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Figure 2

De molding test sample

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Figure 3

Machinability test

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Figure 4

Detail of lower mold half

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Figure 5

Detail of upper mold half

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Figure 6

Lower half with mold adapter and separator device

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Figure 7

Extrusion contour

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Figure 8

Pockets for metal plates

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Figure 9

Finished lower mold half with features

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Figure 10

Mold adapter and separating device

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Figure 11

Dimensions of FDM filament lay up

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Figure 12

Lower mold half after breaking the mold

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Figure 13

Sanding of the FDM surface

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Figure 14

Filaments start breaking off the surface

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Figure 15

Bigger parts of the surface break off

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Figure 16

Section of full scale mold, PPSF features bolted to base platen

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Figure 17

Part with pronounced horizontal line



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