DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA

DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING

IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

SURFACE ROUGHNESS INVESTIGATIONS OF ABS PATTERN

BASED INVESTMENT CASTINGS AFTER ADVANCEMENTS IN
SHELL MOULDING
Rupinder Singh1, Vishal Mahajan2
1-2
Department of Production Engineering
Guru Nanak Dev Engineering College Ludhiana-141006, INDIA

ABSTRACT
In the present work surface roughness investigations have been made on ABS pattern based
investment castings after advancements in shell moulding for replication of biomedical
component having a real 3D shape. For the present study a hip joint was selected as one of a
real 3D biomedical implant. A hip joint, made of ABS material, was fabricated as a master
pattern by fused deposition modelling (FDM). After preparation of master pattern, mold was
made by deposition of primary (1), secondary (2) and tertiary (3) coatings with the
addition of nylon fiber (1-2cm in length) of 1.5D. This study outlines the replication
procedure of hip joint in detail from ABS master pattern to a final implant. Further for
present case study surface roughness is minimum for 9 number of slurry layers coated on
the ABS pattern with the addition of nylon fibers in 1 and 2 coat only.

NOMENCLATURE
1: Primary
2: Secondary
3: Tertiary
FDM: Fused deposition modelling

1. INTRODUCTION
FDM is one of the rapid prototyping (RP) technology by which physical objects (replicas)
usually of ABS material is created directly from CAD data (Cheah et al., 2005, Patel et al.,
2012, Cheng et al., 2012). These replicas are highly accurate in size and shape (Chhabra and
Singh, 2011). Figure 1 shows schematic of FDM process.

Figure 1 Schematic of FDM process (Amira et al., 2011)

Investment casting process involves the production of engineering castings using an

expandable pattern; usually wax (Babu et al., 1990). The term investment casting derives
from the characteristics use of mobile ceramic slurry to form a mould with extremely smooth

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

surface qualities (Jones and Yuan, 2003a). Figure 2 shows basic steps involved in investment
casting process (as: (a) pattern production, (b) pattern assembly, (c) investment, (d) de-
waxing, (e) casting, (f) knock-out, (g) cutoff, and (h) finishing and inspection). The patterns
prepared (at step a) are assembled (at step b) and dipped into the slurry and sprinkled with
coarse refractory sand and dried (step c). This process is repeated until specific mould
thickness is attained. After this de-waxing operation (step d), pouring of molten metal (step
e), knock-out (step f), cut off (step g) and finishing operation (step h) is performed.
Some researchers have highlighted developments in ceramic materials that have currently
been implemented to explore possible methods for the improvement of shell performance
(Jones and Yuan, 2003b, Liao et al., 2011). These studies outlined that inorganic or organic
fibers can be used as ingredients of slurry in order to rapidly increase the process of stucco
coating. Nylon fibers in a water based silica binder can be used as an alternative to increase
the mould thickness and at the same time it replaces costly liquid polymer addition in
investment casting mould. The unique properties of fiber modified system have been found to
be a promising alternative for the standard investment casting industry and with this
mechanical properties have been improved (Sidhu et al., 2008).

Figure 2 Basic steps in investment casting (Singh, 2011, Singh, 2012, Singh and Singh, 2012)

2. BACKGROUND AND REVIEW

The literature review reveals that a lot of research work has been reported on advancement in
shell moulding for investment casting and FDM process optimization. But hitherto very less
work has been reported on surface roughness of cast component after reduction in cycle time
of the investment castings prepared (by advancement in shell moulding) with ABS patterns.
So in the present work it is proposed to study the surface roughness of cast component
prepared by investment casting process for ABS based patterns after reduction in cycle time
based upon advances in shell moulding. For present study, a component of biomedical
application has been selected as the benchmark. The detailed drawing (see Figure 3) for the
benchmark was made using CATIA (CAD software). This drawing serves as the input to the
FDM machine for development of casting pattern. The pattern thus developed is used for
investment casting process. Further, the lead cycle time of the investment casting process has
been reduced by optimizing the different slurry layers and the combinations required for shell
building. Finally this process will prove very economical if used for batch production.

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

Figure 3 Benchmark (hip joint)

Figure 4-9 respectively shows stirring mechanism in slurry tank, slurry coating by dipping the
assembled tree in the slurry tank, final coated nylon added pattern, de-waxing setup, shell
prepared after de waxing and finally casted hip joint. All experiments have been conducted in
controlled environment and SS316L has been used for casting.

Figure 4 Stirring mechanism Figure 5 Slurry coating by Figure 6 Final coated nylon
in slurry tank dipping the assembled tree in added pattern
the slurry tank

Figure 7 De-waxing setup Figure 8 Shell prepared after Figure 9 Finally casted hip
de waxing joint

3. EXPERIMENTATION
Pilot experimentation was conducted for finding the range of process parameters (like:
number of slurry layers, material of pattern and nylon addition in primary (1), secondary
(2), and tertiary (3) coat). Nylon fibre size 1-2cm and of weight 1.5daniel has been mixed
with 1, 2 and 3 coat. After conducting the pilot experimentation it has been observed that
input parameters (like: number of layers, material of pattern and nylon addition in 1-2-3
coat) have a significant effect on the dimensional accuracy of part. Based upon trial runs of
pilot experimentation, selected levels of input parameter for final experimentation are shown
in Table 1.

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

Table 1. Input parameters

Parameter1 Parameter2 Parameter3
Number of layers Pattern material Nylon fibre mixed in 1, 2 and 3 coat
L1 L2 L3 L1 L2 L3 L1 L2 L3
ABS dipped Nylon fibre
Nylon fibre Nylon fibre
8 9 10 Wax in wax (ABS ABS in 1, 2 and
in 1 in 1 and 2
+ Wax) 3
Experiments are conducted in accordance to Taguchi L9 orthogonal array. Control log of
experimentation is shown in Table 2.

Table 2. Control log of experimentation

Number of Nylon fibre mixed in 1, 2 and 3
S. No. Pattern material
layers coat
1. 8 Wax Nylon fibre in 1
2. 8 ABS + Wax Nylon fibre in 1 and 2
3. 8 ABS Nylon fibre in 1, 2 and 3
4. 9 Wax Nylon fibre in 1 and 2
5. 9 ABS + Wax Nylon fibre in 1, 2 and 3
6. 9 ABS Nylon fibre in 1
7. 10 Wax Nylon fibre in 1, 2 and 3
8. 10 ABS + Wax Nylon fibre in 1
9. 10 ABS Nylon fibre in 1and 2

4. RESULTS AND DISCUSSION

The surface roughness was measured using surface roughness tester (perthometer). Results
for surface roughness measurements are shown in Table3.

Table 3. Results for surface roughness

Nylon fibre mixed in 1, 2 Surface roughness (m)
Number Pattern and 3 coat (Ra value)
S. No.
of layers material
R1 R2 R3
1. 8 Wax Nylon fibre in 1 2.61 2.2 2.77
2. 8 ABS + Wax Nylon fibre in 1 and 2 2.26 2.31 2.42
3. 8 ABS Nylon fibre in 1, 2 and 3 2.25 2.12 2.62
4. 9 Wax Nylon fibre in 1 and 2 1.31 1.22 1.55
5. 9 ABS + Wax Nylon fibre in 1, 2 and 3 1.68 1.74 1.55
6. 9 ABS Nylon fibre in 1 1.69 1.71 1.62
7. 10 Wax Nylon fibre in 1, 2 and 3 2.81 2.89 2.74
8. 10 ABS + Wax Nylon fibre in 1 2.25 2.76 2.2
9. 10 ABS Nylon fibre in 1and 2 3.55 3.12 3.69

Here R1, R2 and R3 are three repetitions for experimentation in order to reduce the
experimental error. Based upon Table 3, Table 4 shows signal to noise (S/N) ratio for surface
roughness. These results are for lower the better type problem, as because minimum
deviation is required for better surface finish. Further based upon Table 4, Figure 10-12
shows variation of S/N ratio and surface roughness v/s no. of layers, pattern material and
nylon fiber mixed in 1, 2 and 3 coat respectively.

Table 4. S/N ratio for surface roughness

S. No. Sum of square S/N ratio

1. 6.441667 -8.08998
2. 5.433367 -7.35069
3. 5.473767 -7.38286
4. 1.869 -2.71609

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

5. 2.750833 -4.39464
6. 2.801533 -4.47396
7. 7.9186 -8.98648
8. 5.840033 -7.66415
9. 11.98433 -10.7861

Figure 10 Variation of S/N ratio and surface roughness v/s no. of layers

0 3.5
S/N data 3
-2
2.5

Surface Roughness
S/N Ratio (dB)

(Ra in microns)
-4 2
-6 1.5
1
-8
0.5
-10 0
8 9 10
Number of Layers

Figure 11 Variation of S/N ratio and surface roughness v/s material of the pattern
-5.5 2.6
2.5
-6
2.4 Surface Roughness
(Ra in microns)
S/N Ratio (dB)

-6.5 2.3
-7 2.2
2.1
-7.5 S/N data
2
Raw data
-8 1.9
1 2 3
Material of Pattern
(Note: 1: Wax, 2: ABS+ Wax, 3: ABS)

Figure 12 Variation of S/N ratio and surface roughness v/s nylon fibre addition in v/s nylon
fiber mixed in 1, 2 and 3 coat.
-6.6 2.4
-6.65 2.35
-6.7
Surface Roughness

2.3
S/N Ratio (dB)

(Ra in microns)

-6.75
-6.8 S/ 2.25
-6.85 Ra
2.2
-6.9
-6.95 2.15
-7 2.1
4
Nylon 5
fiber mixed 6 and 3 coat.
in 1, 2
(Note: 4: Nylon fiber mixed in 1coat, 5: Nylon fiber mixed in 1and 2coat, 6: Nylon fiber mixed in 1, 2 and 3 coat)

Further Figure13 shows percentage contribution of input parameters for surface roughness
(which is highly influenced by the no. of layers). Table5 shows the percentage contribution of
input parameters and experimental error calculations. These results are valid for 95% level of
confidence. As observed from Fig. 10-12, 9 no. of slurry layers with ABS+ Wax pattern

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

material and nylon fiber addition in 1 coat is giving maximum S/N ratio and minimum
surface roughness. This is because for nylon modified shells, retention rate is increased and
this leads to a thicker coat compared to other. Further production cycle has been saved by 8
hours. Also addition of nylon fibers dramatically increases the fired permeability at casting
temperatures, mainly due to increased porosity networks left after the fiber burn out. This is
of great benefit to the casting process, allowing increased transport of air displaced from the
mould cavity. The addition of nylon fibre dramatically increased the fired permeability at
casting temperatures, mainly due to increased porosity networks left after the fibre burn out.
This is of great benefit to the casting process, allowing increased transport of air displaced
from the mould cavity. Finally confirmatory experiment was conducted based upon
optimized settings suggested by Taguchi design and percentage improvement in surface
roughness is 3.13%. These results are in line with the observations made by other
investigators (Pattnaik et al., 2012, Singh, 2013).

Figure 13 Percentage contributions of input parameters for Surface roughness

Number of Layers
Material of Pattern
Nylon addition in primary, secondary and tertiary Coating
Error

0% 10%
4%

86%

Table 5 Percentage contributions of input parameters for Surface roughness

Percentage
Input parameters Sum of square
contribution
Number of Layers 44.32023 85.97172
Material of Pattern
2.080764 4.036235

Nylon addition in 1, 2 and 3 Coatings 0.076167 0.147748

Error 5.074944 9.844301

5. CONCLUSIONS
The casting of hip joint has been successfully developed by combining FDM based ABS
patterns and investment casting process. As regard to use of nylon fiber in shell production is
concerned, drain time was reduced.The surface roughness is better with 9 number of slurry
layers coated on an ABS+ Wax pattern with the addition of nylon fibers in 1coat only. The
results of study suggests that for surface roughness the contribution of no. of slurry layers,
type of pattern material and nylon fiber addition in 1, 2 and 3 coat is 86%, 4% and 0.14%
respectively. Further studies may be focused on more number of input parameters and their
levels to optimize the number of refractory slurry and stucco layers to be invested on ABS
pattern by fiber addition to get a component with optimized setting.

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 DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016

ACKNOWLEDGEMENTS
The authors are thankful to All India Council for Technical Education, New Delhi under NCP.

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