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<p>The shrinkage deformation mechanism in the investment casting process is unavoidable. When the deformation is substantial enough to exceed the dimensional tolerance limit of the product, it turns into a product defect that needs to be resolved. One of the well-known, fast, and inexpensive improvement methods is reverse deformation compensation on the wax pattern design. This study presents an implementation of the reverse deformation compensation method on a 316L stainless steel manifold product which initially exhibited excessive bending beyond dimensional tolerance due to significant shrinkage deformation. The defect was mitigated by applying reverse deformation compensation, designed using a parabolic equation. Finite element method (FEM)-based numerical simulations and 3D scan overlay analysis were employed to accelerate the optimization of the compensation. The target dimensional deviations were successfully corrected to within a <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_15750_Article_IEq1.gif" Format="GIF" Height="13" Rendition="HTML" Resolution="72" Type="Linedraw" Width="19" /> </InlineMediaObject> <EquationSource Format="TEX">\(\pm\)</EquationSource> <EquationSource Format="MATHML"><math> <mo>±</mo> </math></EquationSource> </InlineEquation> 0.30&#xa0;mm tolerance by applying a full-parabolic compensation with a peak of 1.50&#xa0;mm on the long side (<i>LS</i>) and a half-parabolic compensation with a peak of 1.20&#xa0;mm on the short side (<i>SS</i>). Quantitatively, the maximum LS distortion was reduced from 1.22 to 0.13&#xa0;mm—an average reduction of 88.71%—while the SS distortion decreased from 1.21 to 0.14&#xa0;mm, an 82.12% reduction. The validated numerical model showed excellent accuracy, with <i>R</i>-squared values ranging from 0.910 to 0.998 across multiple observation points. It also accurately predicted the presence of high local residual stress in the shell mold, identified as the root cause of the distortion. This study offers practical insights for investment casting practitioners, particularly in addressing bending-type distortion defects.</p>

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Experimental and numerical investigation of shell mold deformation and compensation measure in precision casting of 316L stainless steel manifold

  • 期刊论文

  • 发表日期：

    2025年5月24日

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  • Chieh-Fong Lin,
  • Chia-Yu Kao,
  • Chen-Ming Chen,
  • Imang Eko Saputro,
  • Intan Mardiono,
  • Sukhoiri Khoiruddin,
  • Cheng-Fu Huang,
  • Sheng-Chan Lee,
  • Chien-Wei Chan,
  • Yiin-Kuen Fuh

摘要

The shrinkage deformation mechanism in the investment casting process is unavoidable. When the deformation is substantial enough to exceed the dimensional tolerance limit of the product, it turns into a product defect that needs to be resolved. One of the well-known, fast, and inexpensive improvement methods is reverse deformation compensation on the wax pattern design. This study presents an implementation of the reverse deformation compensation method on a 316L stainless steel manifold product which initially exhibited excessive bending beyond dimensional tolerance due to significant shrinkage deformation. The defect was mitigated by applying reverse deformation compensation, designed using a parabolic equation. Finite element method (FEM)-based numerical simulations and 3D scan overlay analysis were employed to accelerate the optimization of the compensation. The target dimensional deviations were successfully corrected to within a \(\pm\) ± 0.30 mm tolerance by applying a full-parabolic compensation with a peak of 1.50 mm on the long side (LS) and a half-parabolic compensation with a peak of 1.20 mm on the short side (SS). Quantitatively, the maximum LS distortion was reduced from 1.22 to 0.13 mm—an average reduction of 88.71%—while the SS distortion decreased from 1.21 to 0.14 mm, an 82.12% reduction. The validated numerical model showed excellent accuracy, with R-squared values ranging from 0.910 to 0.998 across multiple observation points. It also accurately predicted the presence of high local residual stress in the shell mold, identified as the root cause of the distortion. This study offers practical insights for investment casting practitioners, particularly in addressing bending-type distortion defects.