ME 6018 ADDITIVE MANUFACTURING

Transcription

1 ME 6018 ADDITIVE MANUFACTURING 1 SYLLABUS UNIT I Introduction UNIT II CAD & Reverse Engineering UNIT III UNIT IV Liquid Based & Solid Based Additive Manufacturing Systems Powder Based Additive Manufacturing systems UNIT V Medical& Bio Additive Manufacturing 2 1

2 Books Rapid Prototyping: Principles & Applications, Chua C.K, Leong K.F & Lim C.S (Hard copy & E Book) Rapid Prototyping, Gebhardt A Rapid Prototyping & Engineering Applications : A too box for prototype development, Liou L.W. & Liou F.W (Hard Copy) Rapid Prototyping : Theory & Practice, Kamrani A.K. & Nasr E.A (Hard copy & E Book) Rapid Tooling: Technologies & Industrial Applications, Hilton P.D & Jacobs P.F Rapid Manufacturing, D.T. Pham and S.S. Dimov, (E Book) 3 Introduction Types of Mfg. Metal Forming Bending, spinning, drawing, and stretching Metal Casting Metal Removal machining Metal Joining welding, brazing Additive Manufacturing/Rapid Prototyping / 3D Printing 4 2

3 Introduction Prototyping What is a prototype? A prototype is an early sample, model, or release of a product built to test a concept or process or to act as a thing to be replicated or learned from Prototyping serves to provide specifications for a real, working system rather than a theoretical one 5 Introduction Types of Prototype A Proof of Principle Prototype serves to verify some key functional aspects of the intended design, but usually does not have all the functionality of the final product. A Working Prototype represents all or nearly all of the functionality of the final product. A Visual Prototype represents the size and appearance, but not the functionality, of the intended design. A Form Study Prototype is a preliminary type of visual prototype in which the geometric features of a design are emphasized,withlessconcernforcolor,texture,orother aspects of the final appearance. 6 3

4 Introduction Types of Prototype A User Experience Prototype represents enough of the appearance and function of the product that it can be used for user research. A Functional Prototype captures both function and appearance of the intended design, though it may be created with different techniques and even different scale from final design. A Paper Prototype is a printed or hand drawn representation of the user interface of a software product. Such prototypes are commonly used for early testing of a software design, and can be part of a software walkthrough to confirm design decisions before more costly levels of design effort are expended. 7 Unit I : Introduction Overview History Need Classification Additive Manufacturing Technology in product development Materials for Additive Manufacturing Technology Tooling Applications 8 4

5 Overview Prototyping Rapid Prototyping Rapid Tooling Additive Manufacturing / 3D Printing Rapid Manufacturing 9 Rapid Prototyping (Add. Mfg.) Building 3D parts directly from their computer models without going through the mfg. steps such as process planning and tool mfg. 10 5

6 Need for RP (AM) Introducing new products at ever increasing rates is crucial for remaining successful in a competitive global economy Decreasing product development cycle times and increasing product complexity require new ways to realize innovative ideas 11 Technologies needed for AM Feature based design Design for manufacturability analysis Simulation Computational prototyping (mathematical) Virtual prototyping Physical prototyping 12 6

7 Technology for AM Layered Manufacturing Or Solid Freeform Fabrication (SFF) 13 History 1890 Blanther layered method for making a mould for topographical relief maps 14 7

8 History 1940 Perera Cardboard sheets stacking 1985 Commercial development started 1988 First commercial RP machine 3D Systems 15 Impact of RP & T on Product Development Design cost 70% i.e. once the design is released 70% of the cost of the product is fixed. Design 70% Material 20% Labour 5% Overheads 5% 16 8

9 Benefits Investments in design yields the highest returns for manufacturing companies. Improves almost all sensible aspects of products & makes it more competitive; comparatively risk free and inexpensive It contributes in 3 main areas to improve competitiveness. Cost : reduce mfg. cost & recurring cost Acceptability: improves product uniqueness, appearance, user friendliness, reliability & safety Service: improved packaging ensures safe delivery and reduce repair & maintenance. 17 Impact of change on cost Concept stage Design Stage Tooling Stage Testing Stage Post Release X 10X 100X 1000X 10000X 18 9

10 Benefits of Prototype Working prototypes play a vital role for proving the functions of the new technology Plastic Prototype : one go product ; production moulds for plastics are very expensive & requires considerable fabrication time. 19 Advantages of AM in RP Lower cost of prototyping Shorter lead times Improved total product quality 20 10

11 Role of AM in Product Dev. Conceptual Design Detailed Design Manufacturing CAD Virtual Model RE Physical Model Tooling Additive Manufacturing RE Reverse Engineering 21 Attributes of AM Can build arbitrarily complex 3D geometries Process planning is automatic, based on CAD model Use a generic fabrication machine i.e. do not require part specific fixturing & tooling Requires minimal or no human intervention to operate 22 11

12 General AM Process Solid 3D CAD model is decomposed into cross sectional layer representation in the process planner Planner generates trajectories for guiding material additive processes to physically build up these layers in an automated fabrication machine to form the object Sacrificed supporting layers are also simultaneously built up to fixture the object 23 Classification of AM Based on the initial form of material Liquid Based Processes Solid Based Processes Powder Based Processes 24 12

13 Liquid Based Process Initially the material is in liquid state. Using a process called Curing the liquid is converted into solid state Processes: Stereolithography (SLA) Solid Ground Curing (SGC) 25 Solid Based Process The material is in the form of wire, roll, laminate & pellets Processes: Laminated Object Manufacturing(LOM) Fused Deposition Modeling (FDM) 26 13

14 Powder Based Process Powder in grain like form is used Processes: Selective Laser Sintering (SLS) 3D Printing (3DP) Direct Metal Laser Sintering (DMLS) Laser Engineered Net Shaping (LENS) Selective Laser Melting (SLM) Electron Beam Melting (EBM) 27 Rapid Tooling Tooling requires long time & huge costs AM technique for Prodn. Tooling has advantages: Reduces cost Saves time Gives a competitive edge at the crucial stage of product development 28 14

15 Rapid Tooling.. Tooling for casting, molding & sheet metal Tooling is critical if the product shapes are complex. Computer based system for designing the tooling for a particular application can greatly reduce the tooling lead time by minimising the iteration required to fix mfg. or quality problems. 29 Rapid Tooling Using AM Master Model (master pattern for example) of the product in a variety of materials such as ABS Acrylonitrile Butadiene Styrene Acrylate Polycarbonate Nylon Wax Metal 30 15

16 Materials for Rapid Tooling Thermosetting polymers Epoxy resins Polyurethanes (elastomers & foam) Silicones Metals with low melting point Wax 31 Classification of RT Process Indirect RT: the starting point is the RP of the component for which tooling is required Direct RT: the tool is directly manufactured in layers 32 16

17 Characteristics of RT Tooling time Tooling cost Tool life Tolerance : 20% of conventional method : 5% of conventional method : considerably less : wider than for conventional 33 Benefits of AM To the product designer Increase product complexity with little effect on lead time and cost Optimize the part design to meet customer rquirements Improved design creativity Valuable feed back on the design can be obtained from various sources 34 17

18 Benefits of AM To the Manufacturer Early realization of profit Reduced cost due to reduction in wastage & scrap Reduced labour content Design errors like too thin walls, misaligned apertures can be identified and solved at early stage Tooling can be done only when the concept is refined 35 Benefits of AM To the Marketer Reduced time to market Reduced risk of product failure Make products meeting customer requirements Test marketing of new products is possible Limited edition of variety of conceptual prototypes can be launched followed by mass production 36 18

19 Benefits of AM To the customer Gets products which meet more closely the individual needs and wants 37 Applications of AM Concept models Present ideas in mock up models or prototype of product for final presentation Enormous time is saved Even intricate details can be shown 38 19

20 Applications of AM Market Research Several different variations in design models can be made simultaneously and the best one can be selected. 39 Applications of AM Tender Model Physical 3D part model can be given to the subcontractor for a more realistic quote Assists the vendor in deciding the parting lines 40 20

21 Applications of AM Wind Tunnel Models RP models of planes automobiles trains Buildings & structures can be made to test in wind tunnels 41 Applications of AM Model for stress analysis RP models are used for experimental stress analysis of parts under loads by photo elastic stress analysis and other analytical methods 42 21

22 Applications of AM Medical Applications To make one off replicas of bones CT Scan data prototype part (bone) create ceramic shells for investment casting of metallic replacement parts 43 Applications of AM Rapid Tooling To make injection molds to introduce a number of designs in the market during peak season Final hard tooling is done only for those which perform best in the market 44 22

23 Characteristics of RT 45 END OF UNIT I 46 23