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Nouvelles méthodologies de conception de moules et noyaux architecturés de fonderie sable fabriqués par fabrication additive

Abstract : Additive manufacturing impacts the traditional skills of the foundry profession. New machines depositing layer by layer sand and binder allow a manufacturing of custom foundry tools, unitary, and more complex. In this thesis, we are interested in the development of new methodologies for the design of molds and cores for sand foundries. The reflection takes into account the geometrical design, the design constraints, the constraints of additive manufacturing and foundry techniques. A first chapter describes the state of the art, indicating that research opportunities are to be seized. The second chapter proposes a design methodology for optimizing the mass and controlling the mold’s cooling speed by varying - - the thickness and local thermal conductivity of the mold. A third chapter deals with the study of the thermal impact by the architecture of the walls.The fourth chapter offers a cluster design methodology, allowing the optimization of the compactness of the manufacturing build volume. This method also proposes a novel design by nesting the casting sprues. Finally, the fifth chapter proposes to overcome the problem of hot spots by using multi-material additive manufacturing.To support these chapters, tests of thermal conductivity, mechanical resistance, simulations, manufacturing, casting, and analyzes are carried out. Thus, these new manufacturing guidelines will benefit the founders of tomorrow.
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Submitted on : Wednesday, February 12, 2020 - 12:11:36 PM
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Tugdual Le Neel. Nouvelles méthodologies de conception de moules et noyaux architecturés de fonderie sable fabriqués par fabrication additive. Génie mécanique [physics.class-ph]. École centrale de Nantes, 2019. Français. ⟨NNT : 2019ECDN0022⟩. ⟨tel-02475842⟩

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