Using numerical simulation with rapid prototyping and investment casting

This article presents an approach to making an aluminum automobile prototyp e by integrating numerical simulation and rapid prototyping into investment casting. Following the integrated prototype procedure, a sound aluminum (A l-Si-7Mg) manifold prototype with excellent contour and an acceptable surfa ce finish teas made with only one casting trial. This study indicated that the potential of the rapid prototyping-investment casting coupling could be more effective with the aid of integrated numerical simulation, and numeri cal optimization of the casting parameters aids in minimizing the risk of c asting failure and avoiding the iterative casting trials.