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A Feature-Based Approach to Automated Design of Multi-Piece Sacrificial Molds



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S Dhaliwal S K Gupta1 J Huang M Kumar Mechanical Engineering Department and Institute for Systems Research University of Maryland College Park MD 20742 1 A Feature Based Approach to Automated Design of Multi Piece Sacrificial Molds This paper describes a feature based algorithm for automated design of multi piece sacrificial molds Our mold design algorithm consists of the following three steps First the desired gross mold shape is created based on the feature based description of the part geometry Second if the desired gross mold shape is not machinable as a single component then the gross mold shape is decomposed into simpler geometric components to make sure that each component is machinable using 3 axis CNC machining The decomposition is performed to ensure that each component is accessible to end milling tools and decomposed components can be assembled together to form the gross mold shape Finally assembly features are added to mold components to eliminate unnecessary degrees of freedom from the final mold assembly to facilitate molding DOI 10 1115 1 1419195 Introduction Molded parts are used extensively because they produce netshape parts that require minimal secondary operations On the basis of the number of parting surfaces in a mold molds can be divided into two piece molds and multi piece molds Multi piece molds refer to molds having more than one parting surface and hence more than two components These molds can produce complex parts that cannot be made using two piece molds They enable the use of molding for making parts that were previously manufactured using other processes Since they have more than one parting surface they can be decomposed along different directions and thus can be used to make geometrically complex parts Sacrificial molds refer to molds that can be destroyed after the part has been produced They are generally made of low melting point materials such as wax and are typically destroyed by heating the mold part assembly Moreover the wax



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