WEEK 11: MOLDING AND CASTING



GROUP ASSIGNMENT
REVIEW THE SAFETY DATA SHEETS FOR EACH OF YOUR MOLDING AND CASTING MATERIALS, THEN MAKE AND COMPARE TEST CASTS WITH EACH OF THEM.


In this week we have study about the Safety tools for the moldeing and Casting, in our Lab there are deffernt type of material but we have choose two materails for the Molding we select The MOLDMAX-60, and for the Casting SMOOTH CAST-305



Molding Material MOLD MAX-60:

Mold Max™ 60 is a Shore 60A tin catalyzed silicone mold rubber formulated for applications requiring high heat resistance (up to 560°F/294°C). It features a low mixed viscosity and cured rubber exhibits very low linear shrinkage. Parts A & B are mixed 100A & 3B by weight. Pot life is 40 minutes and cure time is 24 hours. Applications include making foundry patterns, flat pattern reproductions and casting low-melt metal alloys such as tin and pewter.for more details HERE.

MOLD MAX 60 SAFETY 60 DATASHEET REVIEW:

MOLD MAX 60

PRODUCT/CHEMICAL NAME: MOLD MAX 60 PART A:

  • Hazards Identification - Not hazardous according to United States Occupational Safety and Health Administration (OSHA).
  • Inhalation - Remove source(s) of contamination and move victim to fresh air.
  • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
  • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse.
  • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
  • After first aid, get appropriate in-plant, paramedic, or community medical support.
  • Flash Point - 300 °F
  • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. Use good general housekeeping procedures.
  • Storage Requirements - Store in cool dry, well-ventilated area
  • Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eyeand face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
  • Toxicological Information:
  • Eye Effects: Irritation
  • Skin Effects: Irritation
  • Carcinogenicity: None Determined
  • Mutagenicity: None Determined
  • Teratogenicity: None Determined

PRODUCT/CHEMICAL NAME: MOLD MAX 60 PART B:

  • Hazards Identification
    • Harmful if swallowed.
    • Irritating to eyes, respiratory system and skin.
    • Harmful to aquatic organisms may cause long term adverse effects in the aquatic environment.
    • Inhalation - Remove source(s) of contamination and move victim to fresh air. If breathing has stopped, give artificial respiration, then oxygen if needed. Contact physician immediately.
    • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
    • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse; seek medical attention if rash develops.
    • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
    • After first aid, get appropriate in-plant, paramedic, or community medical support.
    • Flash Point - 150 °F
    • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. If ventilation is not sufficient, wear proper respiratory equipment. Reseal partial containers. Use good general housekeeping procedures.
    • Storage Requirements - Store in cool dry, well-ventilated area
    • Protective Clothing/Equipment - Wear chemically protective gloves and aprons to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eye- and face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
  • Toxicological Information:
    • Eye Effects: Irritation
    • Skin Effects: Irritation
    • Carcinogenicity: None Determined
    • Mutagenicity: None Determined
    • Teratogenicity: None Determined

    SMOOTH-CAST 300 SERIES SAFETY DATASHEET REVIEW:

    SMOOTH CAST 305


    PRODUCT/CHEMICAL NAME: SMOOTH-CAST 305 PART A:

    • Hazards Identification
    • Harmful by inhalation.
    • Irritating to eyes, respiratory system and skin.
    • Limited evidence of a carcinogenic effect
    • Harmful; danger of serious damage to health by prolonged exposure through inhalation environment.
    • Inhalation - Remove source(s) of contamination and move victim to fresh air. If breathing has stopped, give artificial respiration, then oxygen if needed. Contact physician immediately.
    • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
    • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse; seek medical attention if rash develops.
    • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
    • After first aid, get appropriate in-plant, paramedic, or community medical support.
    • Flash Point - 262 °F
    • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. If ventilation is not sufficient, wear proper respiratory equipment. Reseal partial containers. Use good general housekeeping procedures.
    • Storage Requirements - Store in cool dry, well-ventilated area
    • Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eyeand face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
  • Toxicological Information:
    • Hazardous Component: 4, Methylene, bis(phenylisocyanate)

    PRODUCT/CHEMICAL NAME: SMOOTH-CAST 305 PART B:

    • Hazards Identification - Not hazardous according to United States Occupational Safety and Health Administration (OSHA).
    • Inhalation - Remove source(s) of contamination and move victim to fresh air.
    • Eye Contact - Flush eyes with plenty of water. If irritation persists, seek medical attention.
    • Skin Contact - In case of skin contact, wash thoroughly with soap and water; remove contaminated clothing and launder before reuse.
    • Ingestion - Do not induce vomiting unless instructed by a physician. Contact physician immediately
    • After first aid, get appropriate in-plant, paramedic, or community medical support.
    • Flash Point - 262 °F
    • Handling Precautions - Minimize breathing of vapors and avoid prolonged or repeated contact with skin. Wear proper protective equipment. Use good general housekeeping procedures.
    • Storage Requirements - Store in cool dry, well-ventilated area
    • Protective Clothing/Equipment - Wear chemically protective gloves to prevent prolonged or repeated skin contact. Wear protective eyeglasses or chemical safety goggles, per OSHA eye- and face-protection regulations 29 CFR 1910.133 and European Standard EN166. Contact lenses are not eye protective devices. Appropriate eye protection must be worn instead of, or in conjunction with contact lenses.
  • Toxicological Information:
    • Acute Inhalation Effects: None Established
    • Acute Oral Effects: None Established
    • Reproductive Toxicity: None Established
    • Mutagenicity: None Established
    • Teratogenicity: None Established
    • Sensitization: None Established


    INDIVIDUAL ASSIGNMENT
    DESIGN A MOLD AROUND THE STOCK AND TOOLING THAT YOU'LL BE USING, MILL IT (ROUGH CUT + (AT LEAST) THREE-AXIS FINISH CUT),AND USE IT TO CAST PARTS THEN MAKE AND COMPARE TEST CASTS WITH EACH OF THEM


    In this week I decided to make a shape of Anchor which will be casted in wax. The first mold made out of the wax will be the positive shape of the design. I will cast both plastic and metal. After that then make flexible mold by pouring Mold Max 60 and then casting the original material.

    3-D MODEL:

    To make Anchor, first I searched Anchor on Google then I selected and downloaded the simple design. I opened it in online Software to remove it's background and save it as .png formate.

    Now background is removed.

    INKSCAPE:

    Then I import .png image in InkScape for making scalable vector file by using trace bitmap and save that as .svg format.

    Open Anchor in Inkscape.

    click on path select the trace bitmap here, we remove the raster image.

    Select the vector image and remove the Raster.

    Making an SVG formate.

    Saving as .dxf for SolidWorks.


    SOLIDWORKS:

    Start the designing in solid works. First of all open the .dxf file.

    Extrude boss and then give required thickness to the object.


    Now, Anchor is ready for milling.


    OUTER WALLS:

    Box with wall inclinde inside with 45 degree. The reason for making angle 45 deg is that Angles on the side walls are required in order to extract the negative moulding from the mold.


    ASSEMBLING THE PARTS:

    mate the Anchor and Outer wall also save the file in .stl fomate to open in Modela Player 4.



    GENERATING .PRN FILE USING MODELA PLAYER 4:

    Solidwork design is saved in .stl formate. SRM 20 need .prn file for making 3D mold. Modela player 4 is used to make .prn file from .stl file.

    OPEN THE MODELA:

    Open the .stl file in medula

    Select the material you want to use here we select the molding wax.

    Select the machine for milling that you have in your lab in my case we have SRM-20.

    go to set and model then select the origin from where you want to start.

    OPEN MODELING FORM:

    Set the margin from boundary walls by selecting Manual option becasue we wanted to make changes if required.

    ROUGHING

    There are two tool paths. One is roughing and second is finishing. We start with Roughing. Select the roughing type.

    Select the cutting surface top[+Z] because the bit will move on uper side.

    Select the tool width 3mm for roughing. I am using 3mm bit because I wanted the result to come. Here, less than 3mm bit may have chances for bit demage in last I wanted to reducing the machine timing.

    Set the cutting area by choosing the "Partial" option becasue I wanted to cut only required part.

    Set the "Contour Lines" to Up Cut for cutting only upper side.

    bit size 24mm this is the predefined setting we get the good result on this setting.

    Name the process and press the finish button.

    TOOL PATH OF ROUGHING:

    you can view the toolpath by clicking on the button at bottom right.



    FINISHING:

    After roughing, create tool path for finishing.

    Repeat the same steps. Only change the tool size to 1mm because we needed good finishing it comes when the bit size is less due to that it will easily cover all edges/holes of the object.

    Check on Partial then resize the red boundary line inside the box then Next.

    scan lines to X+Y. bit will move in this direction.

    XY speed 16mm this is the predefined setting we are getting good results on this speed.

    Name the process and press the finish button.

    saving the finishing file is under process.



    SIMULATION RESULTS

    you can view the toolpath and simulation by clicking on the button at bottom right. This is the roughing file simulation.

    Now, in last this is the finishing simulation.



    SAVE IT/DIRECTLY RUN TO MACHINE

    Finally press the "Cut" button.

    Now, here you may either give the file directly to machine or you can save them as .prn files for later use.



    MILLING THE MOLD

    After generating .prn files of rough and finishing, place the mold brick into SRM 20. Set the X,Y and Z axis. Then first give the rough.prn file.

    Result After finishing.



    MEASURING THE MATERIAL FOR MOLD

    To know the exact amount of material needed to make mold we first put water in the hard mold and measure the water that come in the mold. By doing this we get to know the idea of total material that is needed to make flexible mold. Always make 20-30% extra material of water weight or you can refer to datasheet of material for gravity density for exact measurement of water to that material.

    this is the measurement of material with water.



    MAKING FLEXIBLE NEGATIVE MOLD

    After making hard positive mold, we need to make negative flexible mold. I choose to make flexible mold with MOLD MAX 60. It is high heat resistant. It can be used for metal casting as well as for other materials too. My idea is to make one mold and cast two different material(metal and plastic). For Mold max 60 ratio of A and B part is 100:3 ratio. First Mix part and then pour into glass and mearsure it. Then put part B with 100:3 ratio. Stir it for around 5-6 mints. Then pour into the Hard mold. According to datasheet of Mold max 60, it take around 24 hours to become solid. I left it for complete day. On next day i take it out gently. Got the good result.

    This is the negative mold.

    I got some bubbles on the negative mold the reason is that I think I did not mix the mold max ratio of A & B well. for fixing this problem I will mix the material more than 10 minutes So, I will get the good result.

    This is the hard and soft mold.



    PLASTIC CASTING

    For plastic casting I am using Smooth-cast 350. The ratio of Part A and B is 100:90. Carefully pour it into the flexible mold wait for 10-15 mints to get solid.

    plastic casting material is getting dry. Carefully take out the plastic from mold.

    This is the final plastic mold.



    HARD MOLD(POSITIVE MOLD)>> SOFT MOLD(NEGATIVE MOLD) >> FINAL CAST





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