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Limit analysis on surface roughness and dimensional accuracy of spray metallic crust for rapid tooling production by metal arc spraying process

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Abstract

Repetitively prototyping several prototypes of the same component using currently available rapid-prototyping equipment can be very costly. Substantial savings can be attained with the use of a metal spray process to produce a crust shell on a rapid-prototyping pattern coated with mould release agent (PVA), and then backing the crust with aluminium granules so as to form rapid mould/tooling (RT). The smoothness of the innermost spray layer and its dimensional accuracy in relation to the RP prototype are factors that ensure good quality of parts replicated by RT. This paper establishes a preliminary model for predicting the upper bound of the former and the lower bound of the latter, which have been experimentally verified by arc spraying zinc onto PVA. The theoretical model permits the prediction of spraying parameters for controlling the achievable surface finishing and dimensional accuracy of a spray in RT production.

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Acknowledgement

This project is partially supported by the City University of Hong Kong, Project No. 7001202.

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Authors and Affiliations

  1. Department of Manufacturing Engineering and Engineering Management, City University of Hong Kong, 83 Tat Chee Avenue, Kowloon Tong, Kowloon, Hong Kong, China

    M. Hua, C. C. Lau & I. K. Hui

  2. Wuhan Research Institute of Materials Protection, 430030, Wuhan, China

    J. Li

Authors
  1. M. Hua
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  2. C. C. Lau
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  3. I. K. Hui
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  4. J. Li
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Correspondence to M. Hua.

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Hua, M., Lau, C.C., Hui, I.K. et al. Limit analysis on surface roughness and dimensional accuracy of spray metallic crust for rapid tooling production by metal arc spraying process. Int J Adv Manuf Technol 23, 720–731 (2004). https://doi.org/10.1007/s00170-003-1712-0

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  • DOI: https://doi.org/10.1007/s00170-003-1712-0

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