Sand Binder Jetting Pattern Application for Reducing Binder Usage
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Solution Overview
Problem
Sand binder jetting methods face challenges in reducing binder usage while maintaining shape and strength, leading to increased production costs and limited industrial adoption due to the inability to adjust binder application effectively and efficiently.
Innovation Solution
A slicing 2D data-based pattern application method that generates internal patterns on layers of the output model, considering set thickness and contour thickness, to optimize binder usage and exclude unnecessary binder application on surface layers, thereby reducing overall binder consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder is sprayed sufficiently to create a rigid mold that can endure pressure of molten metal, then mold strength is improved, but binder usage amount increases and production cost increases
Solution Approach 1:
The patent applies different binder spraying patterns to different regions within the mold cavity. By analyzing the structural characteristics of the mold, the system identifies regions that require higher binder concentration for strength and regions where less binder is needed, creating a non-uniform binder distribution that optimizes both strength and material usage.
Solution Approach 2:
The patent implements selective binder application where only specific areas of the mold cavity receive binder spraying, rather than uniformly spraying the entire cavity. This partial action approach applies binder exactly where needed to maintain structural integrity while avoiding unnecessary binder consumption in areas that don't require reinforcement.
2Strength
If binder is sprayed uniformly to fill the inside of the output model, then mold strength is improved, but production cost increases and sand reuse becomes difficult
Solution Approach 1:
The system transitions from uniform binder application to localized binder application based on the specific geometric and structural characteristics of different regions within the mold cavity. This allows the binder to be applied only where structurally necessary, reducing overall binder consumption and production costs while maintaining adequate mold strength.
3Quantity of substance
If binder usage amount is reduced to decrease production cost, then production cost is reduced, but mold strength may be insufficient to endure pressure of molten metal
Solution Approach 1:
The patent employs region-specific binder spraying patterns that concentrate binder application in areas requiring structural support while reducing or eliminating binder application in areas where structural integrity is already sufficient. This localized approach maintains mold strength at necessary locations while reducing overall binder consumption.
Solution Approach 2:
The system applies binder selectively to specific regions rather than uniformly across the entire mold cavity, performing the binding action only where structurally required. This partial application strategy reduces binder usage while ensuring adequate strength at critical locations.
4Device complexity
If existing sand binder jetting equipment is used without pattern application function, then equipment simplicity is maintained, but binder usage cannot be optimized and production cost increases
Solution Approach 1:
The patent introduces a pre-processing step where the mold cavity is analyzed and binder spraying patterns are planned before the actual binder application. This preliminary pattern generation phase enables optimized binder distribution without requiring complex real-time control systems during the spraying process itself, thus maintaining equipment simplicity while achieving binder optimization.
Data Source
AI summary
Provided is a slicing 2D data-based pattern application method for generating an output code in which the inside of a model is filled with a pattern, so as to reduce a binder usage amount and maintain a strength and a shape in sand binder jetting additive manufacturing. A slicing 2D data-based pattern application method according to an embodiment of the present invention comprises the steps of: generating 2D data by slicing an output model; generating an inner pattern in at least one of layers forming an output model in consideration of the set thickness of the layers and the outer thickness thereof and generating an output code by applying the generated inner pattern. Therefore, the cost of producing an additive manufacturing output can be reduced by reducing the binder usage amount through the application of the inner pattern. In addition, reducing the binder usage amount enables a mold to be destroyed with less force than conventionally used, can increase the proportion of molding sand reuse by reducing the binder usage amount, and can reduce recovery treatment costs of the molding sand. Furthermore, casting defects due to increased ventilation can be reduced.