Fabrication of Dry Connection Through Stamping and Milling of Green-State Concrete

This study addresses the fabrication challenges associated with producing diverse geometries for concrete dry connections, particularly regarding cost, time, and geometric limitations. The research investigates methods for fabricating precise, rebar-free dry connections in concrete, focusing on stamping and green-state computer numerical control (CNC) milling. These methods are evaluated using metrics such as dimensional accuracy, tool abrasion, and energy consumption. In the stamping process, a design of experiments (DOE) approach varied water content, concrete age, stamping load, and operational factors (vibration and formwork) across cone, truncated cone, truncated pyramid, and pyramid geometries. An optimal age range of 90 to 105 min, within a broader operational window of 90 to 120 min, was identified. Geometry-specific exceptions, such as approximately 68 min for the truncated cone and 130 min for the pyramid, were attributed to interactions between shape and age rather than deviations from general guidance. Within the tested parameters, water fraction primarily influenced lateral geometric error (diameter or width), while age most significantly affected vertical error. For green-state milling, both extrusion- and shotcrete-printed stock were machined at 90 min, 1 day, and 1 week. From 90 min to 1 week, the total milling energy increased on average by about 35%, and at one week end-face (head) passes caused substantially higher tool wear, with mean circumference losses of about 3.2 mm for head engagement and about 1.0 mm for side passes. Tool abrasion and energy demand increased with curing time, and extrusion required marginally more energy at equivalent ages. Milling was conducted in two engagement modes: side (flank) and end-face (head), which were evaluated separately. End-face engagement resulted in substantially greater tool abrasion than side passes, providing a clear explanation for tolerance drift in final joint geometries. Additionally, soil-based forming, which involves imprinting the stamp into soft, oil-treated fine sand to create a reversible mold, produced high-fidelity replicas with clean release for intricate patterns. This approach offers a practical alternative where friction and demolding constraints limit the effectiveness of direct stamping.