Three-dimensional printing (3DP) is considered to be one of the important technologies for a new manufacturing mode. When ceramsite sand is used as a 3DP material to produce a mold (core), the printed layer is prone to deviation from the original location. In this study, the continuous stacking of the printed part deviation was termed as pushing dislocation, and a physical model was designed to investigate the pushing dislocation mechanism. When the gravity of the printing layer and the pressure of the sand scraper decreased, or when the supporting force increased, the angle of the sand scraper and the maximum friction of the prelaying layer on the printed part will reduce the pushing dislocation. To optimize the quality of the ceramsite sand mold, experiments on the pushing dislocation were conducted by altering the recoater speed, layer thickness, and bottom support condition (with or without bottom supporting plate). The sample dimensions were obtained by a 3D imaging scanner, and the gas evolution and ignition loss were measured. The results revealed that the dimensional difference of samples continuously decreased and the pushing dislocation was gradually reduced as the recoater speed and layer thickness increased. The pushing dislocation of the X-direction sample was more severe compared with that of the Y-direction sample. Increasing the layer thickness is an effective way of reducing the pushing dislocation. The bottom supporting plate can reduce the pushing dislocation, but the effect was insignificant.
Keywords: ceramsite sand; pushing dislocation; sand casting; three-dimensional printing.
Copyright 2023, Mary Ann Liebert, Inc., publishers.