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Experimental and numerical investigation of shell mold deformation and compensation measure in precision casting of 316L stainless steel manifold.

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Title: Experimental and numerical investigation of shell mold deformation and compensation measure in precision casting of 316L stainless steel manifold.
Authors: Lin, Chieh-Fong1 (AUTHOR), Kao, Chia-Yu1 (AUTHOR), Chen, Chen-Ming1 (AUTHOR), Saputro, Imang Eko1 (AUTHOR), Mardiono, Intan1 (AUTHOR), Khoiruddin, Sukhoiri1 (AUTHOR), Huang, Cheng-Fu2 (AUTHOR), Lee, Sheng-Chan2 (AUTHOR), Chan, Chien-Wei2 (AUTHOR), Fuh, Yiin-Kuen1 (AUTHOR) mikefuh@ncu.edu.tw
Source: International Journal of Advanced Manufacturing Technology. Jun2025, Vol. 138 Issue 9, p4043-4061. 19p.
Subjects: Investment casting, Precision casting, Manufacturing defects, Finite element method, Stainless steel
Abstract: The shrinkage deformation mechanism in the investment casting process is unavoidable. When the deformation is substantial enough to exceed the dimensional tolerance limit of the product, it turns into a product defect that needs to be resolved. One of the well-known, fast, and inexpensive improvement methods is reverse deformation compensation on the wax pattern design. This study presents an implementation of the reverse deformation compensation method on a 316L stainless steel manifold product which initially exhibited excessive bending beyond dimensional tolerance due to significant shrinkage deformation. The defect was mitigated by applying reverse deformation compensation, designed using a parabolic equation. Finite element method (FEM)-based numerical simulations and 3D scan overlay analysis were employed to accelerate the optimization of the compensation. The target dimensional deviations were successfully corrected to within a ± 0.30 mm tolerance by applying a full-parabolic compensation with a peak of 1.50 mm on the long side (LS) and a half-parabolic compensation with a peak of 1.20 mm on the short side (SS). Quantitatively, the maximum LS distortion was reduced from 1.22 to 0.13 mm—an average reduction of 88.71%—while the SS distortion decreased from 1.21 to 0.14 mm, an 82.12% reduction. The validated numerical model showed excellent accuracy, with R-squared values ranging from 0.910 to 0.998 across multiple observation points. It also accurately predicted the presence of high local residual stress in the shell mold, identified as the root cause of the distortion. This study offers practical insights for investment casting practitioners, particularly in addressing bending-type distortion defects. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Experimental and numerical investigation of shell mold deformation and compensation measure in precision casting of 316L stainless steel manifold.
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  Data: <searchLink fieldCode="AR" term="%22Lin%2C+Chieh-Fong%22">Lin, Chieh-Fong</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kao%2C+Chia-Yu%22">Kao, Chia-Yu</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chen%2C+Chen-Ming%22">Chen, Chen-Ming</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Saputro%2C+Imang+Eko%22">Saputro, Imang Eko</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mardiono%2C+Intan%22">Mardiono, Intan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Khoiruddin%2C+Sukhoiri%22">Khoiruddin, Sukhoiri</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Huang%2C+Cheng-Fu%22">Huang, Cheng-Fu</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Lee%2C+Sheng-Chan%22">Lee, Sheng-Chan</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chan%2C+Chien-Wei%22">Chan, Chien-Wei</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Fuh%2C+Yiin-Kuen%22">Fuh, Yiin-Kuen</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> mikefuh@ncu.edu.tw</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jun2025, Vol. 138 Issue 9, p4043-4061. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Investment+casting%22">Investment casting</searchLink><br /><searchLink fieldCode="DE" term="%22Precision+casting%22">Precision casting</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+defects%22">Manufacturing defects</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Stainless+steel%22">Stainless steel</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: The shrinkage deformation mechanism in the investment casting process is unavoidable. When the deformation is substantial enough to exceed the dimensional tolerance limit of the product, it turns into a product defect that needs to be resolved. One of the well-known, fast, and inexpensive improvement methods is reverse deformation compensation on the wax pattern design. This study presents an implementation of the reverse deformation compensation method on a 316L stainless steel manifold product which initially exhibited excessive bending beyond dimensional tolerance due to significant shrinkage deformation. The defect was mitigated by applying reverse deformation compensation, designed using a parabolic equation. Finite element method (FEM)-based numerical simulations and 3D scan overlay analysis were employed to accelerate the optimization of the compensation. The target dimensional deviations were successfully corrected to within a ± 0.30 mm tolerance by applying a full-parabolic compensation with a peak of 1.50 mm on the long side (LS) and a half-parabolic compensation with a peak of 1.20 mm on the short side (SS). Quantitatively, the maximum LS distortion was reduced from 1.22 to 0.13 mm—an average reduction of 88.71%—while the SS distortion decreased from 1.21 to 0.14 mm, an 82.12% reduction. The validated numerical model showed excellent accuracy, with R-squared values ranging from 0.910 to 0.998 across multiple observation points. It also accurately predicted the presence of high local residual stress in the shell mold, identified as the root cause of the distortion. This study offers practical insights for investment casting practitioners, particularly in addressing bending-type distortion defects. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-025-15750-1
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        Text: English
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        PageCount: 19
        StartPage: 4043
    Subjects:
      – SubjectFull: Investment casting
        Type: general
      – SubjectFull: Precision casting
        Type: general
      – SubjectFull: Manufacturing defects
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      – SubjectFull: Finite element method
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      – SubjectFull: Stainless steel
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      – TitleFull: Experimental and numerical investigation of shell mold deformation and compensation measure in precision casting of 316L stainless steel manifold.
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              Text: Jun2025
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