Department of Mechanical engineering

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    Investigating into casting LMPA (low-melting-point alloy) with 3D-printed mould and inspecting quality using 3D scanning
    (Emerald, 2024-07) Kala, Prateek
    Three-dimensional (3D) casting means using additive manufacturing (AM) techniques to print the mould for casting the cast tool. The printed mould, however, should be checked for its dimensional accuracy. 3D scanning can be used for the same. The purpose of this study is to combine the different AM techniques for 3D casting with 3D scanning to produce parts with close tolerance for preparing electrical discharge machining (EDM) electrodes.
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    Performance evaluation of developing electrical discharge machining tools through 3D-printed mould using selective laser sintering and expanding its applications in developing free-form tools
    (Sage, 2024-12) Kala, Prateek
    In the current study, an attempt has been made to find the optimum parameters for electroplating three-dimensional (3D) casted low melting point alloys. The electroplated profile is used as a tool in an electric discharge machining setup. A selective laser sintering process is used for 3D printing the mould in two halves. The mould parts are 3D scanned to find out the dimensional deviation. The low melting point alloy (LMPA) is cast in the mould. The surface roughness of the mould and the pattern are measured. Electroplating the casted LMPA sample is carried out in three stages in search of optimum parameters for getting stable copper deposits. The thickness of copper deposits under varying conditions is measured. The microstructures of cast alloys and copper deposits are analysed using a scanning electron microscope. The casted alloy and copper composition is verified through energy dispersive spectroscopy mapping and X-ray diffraction technique. The developed electric discharge machining electrode successfully performs the machining on the workpiece, and its performance is compared with that of a solid copper tool. The information gained is transferred to prepare the free-form tool using the developed path and is tested on the implant-shaped workpiece.