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PCPro a novel technology for
41/1/2006
BNCE Pusad
Ritesh Bhusari
 
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2 B.N. College of Engineering, Pusad 
1 INTRODUCTION
Rapid Manufacturing is nowadays described as the direct production of finished goods using additive processes out of digital data [2]. Considering theobjective “direct manufacturing of finished products”, it can be applied to allmanufacturing processes that enable this goal out of 3D-CAD data. Thereforesubtractive-, Fraunhofer USA, CCL Page 2 9/27/2004 forming-, shaping- andmolding- procedures and their combinations should be considered, while fulfilling therequirements such as high flexibility.The PCPro method is characterized by the application of CAD/CAM,CNC-milling and casting technologies. Thus, it embraces forming and subtractivetechnologies. Forming such as molding is a well known process for the fabrication of prototypes. The investigated integration of casting systems in CNC machiningcenters accompanied with a high degree of automation offers higher productivity,profitability and quality of the produced parts. PCPro includes data generation of themold/part, casting of the outer contour and milling of the inner contour. Thiscombination allows a flexible control adapted to the demands of the productdevelopment process. The automation of the entire process chain enables RapidManufacturing. This paper will deal with the basics of the PCPro method as well aswith advantages, limitations and the actual development of a prototype machine.These "three dimensional printers" allow designers to quickly createtangible prototypes of their designs, rather than just two-dimensional pictures. Suchmodels have numerous uses. They make excellent visual aids for communicating
 
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3 B.N. College of Engineering, Pusad 
ideas with co-workers or customers. In addition, prototypes can be used for designtesting. For example, an aerospace engineer might mount a model airfoil in a windtunnel to measure lift and drag forces. Designers have always utilized prototypes;RP allows them to be made faster and less expensively.Rapid prototyping is an "additive" process, combining layers of paper,wax, or plastic to create a solid object. In contrast, most machining processes(milling, drilling, grinding, etc.) are "subtractive" processes that remove material froma solid block. RP’s additive nature allows it to create objects with complicatedinternal features that cannot be manufactured by other means.
2. PCpro PROCESS CHAIN
In the following, the basic process steps are explained using a typicalcover part common for example in automotive or electronic industry. The processstarts with the import of the CAD data of the part in a CAD/CAM system.From this CAD data the lower mold is derived, which is easily doneusing a volume modeling CAD system. After the lower mold is generated as a three-dimensional CAD-representation, NC-programming and milling of the lower moldtakes place. For this, the mold block is clamped in the combined milling/castingsystem. The finish machined mold will remain in the system for casting and part
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