製作陶瓷永久鑄造模之研究

Study On Manufacturing Ceramic Permanent Casting Mold

劉弘彬(Hong-Bin Liu)

指導教授 ： 湯華興

國立臺北科技大學/機電學院/製造科技研究所/碩士(2013年)

摘要

石膏模法（plaster mold process）為精密鑄造的種類之一，但石膏模在澆鑄後必須破壞模具取出成品，不能重覆使用。本研究的目的是以氧化鋯及氧化鋁陶瓷材料代替石膏模中的模具，希望做出的鑄造模可以重複使用。
本研究使用的陶瓷模具的製法如下：先用3D繪圖軟體將模穴繪製出來，並加上氧化鋯或氧化鋁燒結的收縮率（例如：氧化鋯平均收縮率為24.38％，氧化鋁平均收縮率為17~18％），先使用快速原型技術製作氧化鋯及氧化鋁的生坯，再將生坯利用機械加工得到所需的模穴，然後，置於燒結爐中高溫燒結，得到高強度的鑄造模。將陶瓷模具包覆於石膏模內，利用離心鑄造法（centrifugal casting）來澆鑄金屬。
實驗中將測試氧化鋁製品受高熱衝擊及高溫燒結是否會產生崩裂而造成模具損壞。並且將鑄造及模具的設計方式來應用在陶瓷模具中。本文將研究上述條件，來提高陶瓷模的強度及耐用度，而達到能夠重覆使用的目的。本研究成果預期可以應用於高熔點金屬工件的鑄造。

關鍵字

快速原型 ； 氧化鋯 ； 氧化鋁 ； 精密鑄造

並列摘要

Plaster mold process is one of precision castings. However, after casting, the plaster mold must be destroyed if we want to retrieve the product, it cannot be reused. Thus, the aim of this research is substituting gypsum of the plaster mold by ceramic material such as zirconia and alumina. We hope that the resulted casting mold can be used repeatedly.
The manufacturing method of the ceramic mold used in this study are as follows: at first, we draw the mold cavity using 3D graphic software, then, the sintering shrinkage ratio of zirconia and alumina should be added（For instance, the zirconia average shrinkage ratio is 24.38％, the alumina average shrinkage ratio is 17~18％）. Afterward, zirconium and alumina green blocks are produced by rapid prototyping technology, and then the green blocks are machined and are transformed to the desired mold cavities. Furthermore, the mold cavities are placed in a sintering furnace. After high-temperature sintering, we obtain a casting mold with high strength. Finally, the finished ceramic mold is coated with plaster. This ceramic mold was used to casting metal parts with centrifugal casting process.
Experiments will test alumina products by the impact of high temperatures and high-temperature sintering. They were crack sensitive and the ceramic molds could be broken. And the casting mold design and specifications used in the ceramic mold. This paper will study the above mentioned conditions in order to improve the strength and durability of the ceramic mold, so that the purpose of repeated use can be achieved. The results of this investigation may be applied for casting metal parts with high melting point.

並列關鍵字

Rapid prototyping ； Zirconia ； Alumina ； Precision casting

參考文獻

[1] 汪家昌，逆向工程與快速模具投影片上課講義，國立台北科技大學製造科技研究所。

[7] H.H. Tang, F.H. Liu, H.H. Huang and J.S. Lee, "Ceramic Laser Fusion," Journal of Tsinghua University (Science and Technology), vol.42, no. 2, 2002, pp.209-212

[8] H. H. Tang, "Building Ultra-Thin Lasers by Ceramic Laser Sintering," Materials Transactions, Journal of the Japan Institute of Metals, vol. 47, no. 3, 2006, pp. 889-897.

[9] H. C. Yen and H. H. Tang, "Developing a paving system for fabricating ultra-thin layers in ceramic laser rapid prototyping," The International Journal of Advanced Manufacturing Technology, vol. 36, no. 3-4, 2008, pp. 280-287.

[10] 劉俊杰，以新式快速原型製程製作陶瓷永久模具，碩士論文，國立台北科技大學製造科技研究所，台北，2010。