Activity 5
Introduction to Pro/CASTING
Creo 2.0
The cleat shown above has been designed in Pro/ENGINEER and sent to you as an IGES file. Your task
will be to prepare computer models of the die halves in preparation for a direct metal casting process
Background:
From Z-Corporation:
The ZCast Direct Metal Casting process provides the ability to produce cast metal parts from a CAD file
significantly faster and less expensively than traditional prototype casting methods. The process involves
printing molds and cores on a 3D Printer directly from digital data, eliminating the pattern and core box
production step in the traditional sand casting process. Metal is then poured into the 3D printed molds.
The technology allows engineers to prototype parts in metal that were previously cost and time
prohibitive.
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Task 1:
Generate a part that can be used in Manufacturing Mode of Pro/E.
Do this by starting a new part and importing the iges file. Select Get Data – Import from the Model tab to
accomplish this. The iges file is in the MET_306 subdirectory of the V: (pro_e) drive and is named
cleat_1.igs. Add gating and vents as in the next two figures. Save your resultant part.
Vent location on
vertical surface, near
top
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Copy and paste three figures similar to the ones above into a single Word document, to document your
gating. These three figures should fit on a singular page.
Task 2:
Create a work piece (Die Block) large enough to encompass the part.
Do this by beginning a second part and producing a rectangular block.
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Task 3:
Assemble these parts together using the methodology below:
Start a new file of Type Manufacturing, Sub-type of Cast Cavity. Use the default template
(inlbs_mfg_cast), not empty.
Assemble (Cast Tab, Assembly region – Reference Model) and fully constrain the Ref Model (your iges
turned part file). There is a plane that runs down the center of the cleat. It might make sense to align
this plane with the Main Parting plane when assembling. If you have no “Main Parting Pln”, you also have
no “Pull Direction”. This means you didn’t select the correct template.
You may get a message about absolute accuracy. Accept the default.
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Task 4:
Create your volumes by first splitting the work piece and then extracting the volumes.
Select the Volume Split option from the Die Volume pull down in the Cast Geometry region.
Task 5:
“Open” the mold.
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Open the bottom die block. Copy and paste this image (including the model tree) into a Word document.
Open the top part, copy and paste the image (including the model tree) into a Word document
Print the screen captures of the upper and lower die block.
End Level 7
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Begin Level 8.5
Goal: To become more familiar with the latest developments in the casting process.
Method: View the technical presentation (PowerPoint) of Direct Metal Casting using Z Corp 3D Model
810 to produce a RP Model (Griffin_casestudies.ppt in the MET_306 subdirectory on the V: drive).
1) List the Process, Benefits and Limitations of the Direct Casting Method.
2) List the Process, Benefits and Limitations of the Shell Metal Casting Process.
3) List the Process, Benefits and Limitations of the Production Intent Casting Process.
4) List the case studies used for the Production Intent Casting Process.
5) Which process is closest to traditional metal casting (sand casting) and explain why.
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Begin Level 10
Create the core and cavity molds for the chisel handle shown.
This handle is available for downloading from the
V:\Pro_E\MET_306 subdirectory as file
chisel_handle_09_student_ver.prt.1.
Note:
Make sure the absolute accuracy of all the parts and assembly has been set to that of the handle
(reference part).
You will need to create a parting surface using the shadow option.
Save the file as a .pdf (600 dpi) and print it on A size paper on a color printer.
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End Level 10
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