Fundamental Research On Technology Of Rapid Manufacturing High Temperature Resistant Prototype Based On Spray Tooling

In order to respond quickly to changes in the market and the needs of users, the enterprises must adapt to the trend of multi-variety, small batch, rapid manufacturing. With the rapid tooling technology deeply and widely used in industry especially in the automobile industry, the efficiency can be greatly improved, the cost is reduced, and rapid manufacturing is the key. Aiming at rapid manufacturing high temperature prototype for plasma spray tooling technology, the paper proposes direct rapid milling clay composite material with high temperature resistance, to simplify the process, and to avoid the loss of precision in the process of translation. Therefore, based on the traditional milling technology as the theoretical support, material design, drying, properties and processing parameters of clay ceramic material were systematically studied in the processing, and designed the composite materials of clay-mullite high temperature prototype.The main research contents and achievements are shown as follows:1. Analyzing current development and problems in therapid tooling technique, high temperature resistant prototype was manufactured through the silicone mold in the plasma spray tooling technology, and the processing was complex,prototype precision easily lost in the process of replication. A new plasma spray tooling process was proposed based on direct rapid manufacturing high temperature prototype, reducing the process flow.2. A new processing of direct process unbaking clay material was proposed by analyzing the current situation of the ceramic materials machining technology. Aiming at some problems in the process, such as clay soft, chip stick tools, clamping difficult. The drying process was adapted, and the drying system was established by drying experiment and theoretical analysis.Experiments show that the strength of dry clay material was raised, suitable for machine tool clamping and cutting no-stick cutter. The machinability of the clay material was studied that the relationship between the surface quality, the milling force clay prototype and processing parameters were analyzed, at the same time, firing process and shrinkage of the material were studied.3. For poor thermal shock resistance and shrinkage deformation after sintering of pure clay material, the clay-mullite composite material was adapted to process high temperature resistant prototype. The refractory material with good mullite powder was added in the clay materials, at the same time PVA was used as binder, binding mechanism of PVA adhered high temperature resistant composite material was studied. It was proved that the composite material of high temperature resistance, bending strength enhancing and sintering shrinkage reducing.4. For the machinability of high temperature resistant prototype composite materials prepared, the bending strength, chip morphology and surface quality were as the criterion to describe the machinability of materials. It was prove by experiments that the composite material prepared has good machinability. The influence of spindle speed, feed speed, axial depth of cut and other processing parameters on surface roughness of after-drying high temperature prototype was study. The optimal mathematic model was established according to the drying temperature prototype machining parameters by regression methods; through the use of Matlab software and genetic algorithm to solve the optimal processing parameters to reduce the prototype surface roughness, it provides a reliable guarantee for the optimization of machining quality after drying temperature prototype.