Die Cast Prototyping using Plaster Casting with Pressurized Vibration Casting Machine

Abstract

This work is concerned with the development of a new plaster die-casting process that combines pressurization and vibration for the prototyping of die-castings, and also with a plaster die-casting machine that has a structure quite similar to that of an ordinary die casting machine. The machine utilizes an air cylinder for pressurization and a magnetic actuator for vibration. A rapid prototyped pattern is made by the LOM process to prepare a plaster mold. In the process, a plunger in the developed machine simultaneously pressurizes and vibrates the molten metal to fill the plaster mold completely and to facilitate the creation of nuclei in the molten metal, respectively. The developed machine produced a prototype of an end clutch cover with a remarkable improvement in mechanical properties.