OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 6 No. 4 2024 Fig. 10. Porosity distribution in the body of the part casting The analysis of the obtained data shows a decrease in the average deviation of master model growth by 25 % of the fi rst, second and third surfaces. The fl atness deviation of surface 4 decreased by 11.5 % due to the smaller surface area and the smaller angle of its location relative to the table. When making a casting, the mold was fi lled with melt through a slot feeder. As the melt entered the thin areas of the casting, the cooling rate was equalized and gas was removed from the casting. This ensures that there are no shrinkage pores in the body of the TE casting. The distribution of pores in feed and sprue system calculated in the ProCast software is shown in Fig. 10. The entire model has about 13 % porosity. It is found that the defect does not aff ect the critical part of the casting of the part. This fact improves the surface quality and density of the metal. The program performs calculations under ideal conditions. Actual results may diff er from the calculations. Based on the calculation performed, the correctness of the designed casting and SFS is proved. Fig. 11, a shows the master model after correction; the wax model is shown in Fig. 11, b. Fig. 11, c shows the metal casting with SFS, which is separated from the part by a cutoff tool. Metal TE with the fi xing method and the corresponding groove profi le machined by copy-piercing electrical discharge machining method with the obtained metal TE are presented in Figs. 11, g–f. During the experiment, a master model, a wax model, and a metal casting were obtained. Table 7 shows the specifi ed dimensions and roughness of the CAD model and the data obtained by measuring the metal casting. The obtained dimensions and roughness of the metal casting satisfy the specifi ed parameters. According to the results of the experimental study of the use of TE, manufactured using the casting technology with the use of rapid prototyping method to obtain a master model, the surface quality of the profi le groove meets the requirements of the drawing. The taken into account interelectrode gap (IEG) allows for dimensions within the 12th accuracy degree, which meets the requirements of pilot production. Conclusions 1. A methodology for designing and manufacturing a complex-shaped TE using rapid prototyping technology for copy-piercing electrical discharge machining is developed.
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