Analysis of hybrid manufacturing systems based on additive manufacturing technology

Transcription

1 Solid Freeform Fabricatio 2017: Proceedigs of the 28th Aual Iteratioal Solid Freeform Fabricatio Symposium A Additive Maufacturig Coferece Reviewed Paper Aalysis of hybrid maufacturig systems based o additive maufacturig techology Marlo Wesley Machado Cuico, Ph.D., marlocuico@yahoo.com.br Uiversidade de São Paulo campus São Carlos Cocep3D Dalto Alexadre Kai, M.Sc. Potifical Uiversity Catholic of Paraa Abstract: Alog the last year, additive maufacturig techologies has bee provig to be a real game chager i several market segmets. Nevertheless, the mai foudatio of productio ad flexible maufacturig systems geerally cosiders classical techologies. For that reaso, the preset work aim to propose ad ivestigate maufacturig systems which icludes additive maufacturig techologies as part of the mai or secodary productio flow. As result, it was idetified that several marketig segmets, types of compoets ad differet aual volumes ted to be better atteded by hybrid flexible maufacturig systems which icludes additive maufacturig techologies. Key words: Additive maufacturig, Flexible maufacturig Systems, Productio 1. INTRODUCTION Alog the last years, 3d pritig techologies ad additive maufacturig techologies have bee playig a ew role i the market i additio to geerate relevat chages i differet market segmets (WELLER et al., 2015; RAYNA e STRIUKOVA, 2016). I spite of that, theses techologies has majorly bee hadle as sigle machie cells because of extesive fabricatio time i compariso with covetioal maufacturig (JAIN e KUTHE, 2013; BAUMERS et al., 2016; RAYNA e STRIUKOVA, 2016). For that reaso, this work mai goal is to aalyse a hybrid maufacturig system that is based o additive maufacturig techologies i order to compare with covetioal maufacturig systems. The Flexible Maufacturig System (FMS) ca ot the be cosidered a sigle techology, but a set of itegrated ad computer cotrolled techologies. Accordig SLACK et al. (2009),the versatile of FMS provides a capabilities package of the system that ivolves the productio of differet products, without sequecig, without delay i the process cofiguratios, volume productio adjusted accordig to the demad. PANDEY et al. (2016) features FMS i machie flexibility, productio flexibility, mix flexibility, product flexibility, routig flexibility, volume flexibility ad expasio flexibility. Techologies, icludig 3d pritig ad additive maufacturig techologies, allied to a FMS, results i meetig with balace a sustaiable developmet model i the ecoomic, evirometal ad social aspects that have bee seekig sice the ed of the last cetury. As result, (RAYNA et al., 2015; RAYNA e STRIUKOVA, 2016) exposes that additive maufacturig teds to geerate ew market segmets ad busiess models. For this study, we aalysed 2 cases i order to idetify the effect of additive maufacturig o the total productivity metrics. I the first case, a covetioal sad castig maufacturig system is exposed while the secod case icludes additive maufacturig techologies ito the process flow. 1918

2 I this work, we have also idicated where this hybrid maufacturig system is placed i volume-variety diagram, exposig the potetial market segmets that might be favoured by. 2. MATERIAL AND METHODS I order to aalyse the pros ad cos betwee both of maufacturig systems, we defied a basic maufacturig layout i additio to the essetial operatio cost ad time. I Figure 1, the basic layout of sad castig maufacturig system is preseted, where the mai material ad product flow is also highlighted. I this figure, patters ad core moulds are fabricated outside of plat by covetioal methods geerally i wood, alumiium ad steel. I this study, we cosidered this layout as the referece sceario (case 1), while the sceario that icludes additive maufacturig to fabricate patters iside maufacturig plat is the secod study case. The applicatio of additive maufacturig for patters, cores has already bee studied i several works, where the techical feasibility was evideced (ROSOCHOWSKI e MATUSZAK, 2000; RAO et al., 2003; CHEAH et al., 2005; MALAGI et al., 2014; RAYNA e STRIUKOVA, 2016). Figure 1 Simple layout of sad castig maufacturig system The differece betwee those study cases is preseted i Figure 2, where the geeral workflow of job shop sad castig maufacturig system is exposed. Therefore, this study cosiders that this additive maufacturig applicatio, which ca also be cosidered rapid toolig, is goig to be icorporated ito maufacturig system. 1919

3 Figure 2 Workflow of (a) covetioal sad castig maufacturig system ad (b) (a) hybrid sad castig maufacturig system I order to compare both cases, we assumed that all processes remai costats apart from patter ad core makig. I this situatio, the variatio of cost ad time was majorly related to toolig fabricatio ad life-cycle. With regards to toolig life-cycle, previous studies idicated the estimated umber of parts that each sort of toolig support. For that, we aalysed differet types ad shapes of patters ad compared agaist covetioal ad additive maufacturig based systems. I this case, patters sizes varied from 100x100x50mm util 300x300x100mm. I Table 1, the average tool ivestmet is preseted besides average life-cycle. Table 1 - Compariso betwee Toolig material ad maximum supported umber of parts Metal based o (ROSOCHOWSKI e MATUSZAK, 2000; SOARES, 2000) Although some of values are extracted from previous works, further ivestigatio is still eeded to better uderstad the cost-life correlatio. 1920

4 As the toolig cost is cosidered a capital ivestmet, the cotributio of toolig for the part cost is amortised by the volume of parts which is fabricated. Therefore, the total toolig cost might be defied as a fuctio of mouldig tool cost ( C mouldig _ tool ), depreciatio factor ( f d ) ad aual parts amout (N), as show i (1) (REES, 1996; CHATAIN e DOBRACZYNSKI, 1997; FAGADE e KAZMER, 2000). I Additio, we icluded the cost of Additive maufacturig equipmet (Am).. C C mouldig _ tool N f d (1) Therefore, the amortized product cost by product ca be foud by Eq. (2), where is the umber of products produced i the maufacturig system. C i 1 C mouldig _ tool N f d (2) 3. RESULTS AND DISCUSSIONS I this study, we idetified that although toolig that was fabricated by additive maufacturig techologies implies o reduced life, total cost was foud to be lower tha covetioal toolig makig. This ca be see i Figure 3, where a compariso betwee cost amortizatio agaist the umber of fabricated parts is preseted. Figure 3 Compariso betwee toolig fabricated by covetioal ad additive maufacturig techologies O the other had, Figure 5 compares the cost of 1 product covetioal patter makig agaist 1, 2 ad 5 products additive maufacturig patter makig. I this case, it is possible to see that amortized cost of 5 products toolig that were fabricated by additive maufacturig is still lower tha covetioal cost desigated for oly 1 product. I cotrast, this behaviour ca be observed for small ad medium product volumes. 1921

5 Figure 4 Compariso betwee toolig fabricated by covetioal ad additive maufacturig techologies i accordace with the product variety As result of this first aalysis, we ca idetify a ew maufacturig profile that implies i the costat toolig makig. Therefore, each momet that a ew tool is eeded to be fabricated geerates ew opportuity to chage part or product ad icrease variety. The mai implicatio of this ca be see i Figure 5, where a compariso betwee covetioal ad hybrid maufacturig based i additive maufacturig is exposed. Therefore, additive maufacturig was proof to atted either small ad medium volumes with high variety or high volumes with low variety. Figure 5 Aalysis of Product variety over the time agaist productio volume As cosequece of this ew approach, ew ecoomical models might be itroduced ad ew opportuities ca be exploited. At the same way, this ew maufacturig approach also allows the growig of customer iterferece ito desig, whereas ew product updates ca be easily implemeted durig the product life. 4. CONCLUSIONS As cosequece of this work, the compariso of covetioal ad hybrid maufacturig systems which icludes additive maufacturig techologies as part of process was aalysed. I additio, 1922

6 the ecoomical aalysis of patter makig was performed ad additive maufacturig toolig was idetified as more profitable. The aalysis of variety was also doe ad additive maufacturig toolig makig was foud to geerate higher variety tha covetioal toolig with the same cost. Therefore, additive maufacturig was proof to atted either small ad medium volumes with high variety or high volumes with low variety. Additioally, this ew maufacturig approach geerates a ew ecoomical model that might be a game chager, whereas it icreases the collaboratio of customers ito desig, allowig high amout product updates ad product chages durig the product life cycle besides esurig covetioal maufacturig strategies. 5. REFERENCES BAUMERS, M., P. DICKENS, et al. The cost of additive maufacturig: machie productivity, ecoomies of scale ad techology-push. Techological forecastig ad social chage, v.102, p CHATAIN, M. e A. DOBRACZYNSKI. Ijectio Thermoplastiques: Moules: Ed. Techiques Igéieur p. CHEAH, C., C. CHUA, et al. Rapid prototypig ad toolig techiques: a review of applicatios for rapid ivestmet castig. The Iteratioal Joural of Advaced Maufacturig Techology, v.25,.3-4, p FAGADE, A. e D. O. KAZMER. Early cost estimatio for ijectio molded parts. J. of Ijectio Moldig Techology, v.4,.3, p JAIN, P. e A. KUTHE. Feasibility study of maufacturig usig rapid prototypig: FDM approach. Procedia Egieerig, v.63, p MALAGI, R., M. SB, et al. Developmet Of Castig Patter Usig Rapid Prototypig. Iteratioal Joural of Research i Egieerig ad Techology, v PANDEY, R., N. SHARMA, et al. Performace Evaluatio of Flexible Maufacturig System (FMS) i Maufacturig Idustries. Imperial Joural of Iterdiscipliary Research, v.2,.3, p RAO, P. N., Y. LERNER, et al. Rapid Prototypig Applicatios i Metal Castig. Istitutio of Egieers Joural, Malaysia, v.64,.3, p RAYNA, T. e L. STRIUKOVA. From rapid prototypig to home fabricatio: How 3D pritig is chagig busiess model iovatio. Techological forecastig ad social chage, v.102, p RAYNA, T., L. STRIUKOVA, et al. Co-creatio ad user iovatio: the role of olie 3D pritig platforms. Joural of Egieerig ad Techology Maagemet, v.37, p REES, H. Uderstadig Product Desig for Ijectio Moldig: Haser Garder Publicatios p. ROSOCHOWSKI, A. e A. MATUSZAK. Rapid toolig: the state of the art. Joural of materials processig techology, v.106,.1, p SLACK, N., S. CHAMBERS, et al. Admiistração da produção: Atlas SOARES, G. A. Fudição: mercado, processos e metalurgia. Rio de Jaeiro: : COPPE/UFRJ p. WELLER, C., R. KLEER, et al. Ecoomic implicatios of 3D pritig: Market structure models i light of additive maufacturig revisited. Iteratioal Joural of Productio Ecoomics, v.164, p