3D Solid Model Using Printing Technique Using Powder Metallurgy

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1 3D Solid Model Using Printing Technique Using Powder Metallurgy Miss. Dipali P. Dharangaonkar, Dr.R.D.Patil Department of Mechanical Engineering, J.T. Mahajan College of Engineering, Faizpur ABSTRACT Added substance producing, otherwise called 3D printing, fast prototyping or freestyle manufacture,, is the process of joining materials to make objects from 3D model data, usually layer upon layer, as different to subtractive manufacturing methodologies such as machining. The use of Additive Manufacturing (AM) with metal powders is a new and growing industry sector with many of its leading companies based in Europe. It turned into a reasonable procedure to deliver complex metal net shape parts, and not just models, as before. Additive manufacturing now enables both a design and industrial revolution, in various industrial sectors such as aerospace, energy, automotive, medical, tooling and consumer goods. The 3D printing process is an indirect process in two steps. After applying a powder layer on the build platform, the powder is agglomerated thanks to a binder fed through the printer nozzle. The process is frequent until chunks are produced, which shall be then removed carefully from the powder bed, as they are in a «green» stage. The metal part solidication takes place in a second step, during a debinding and sintering operation, sometimes followed by an infiltration step. The 3D printing innovation is more beneficial than laser shaft dissolving and needs no help structure. Besides it provides a good surface quality by using one of several post processing techniques: Peening/Blasting/Tumbling for average of Ra 3.0 μm, Superfinishing for an average of Ra 1.0 μm down to < 1.0μm. But the range of available materials is limited and mechanical properties achieved can be lower than with laser and electron beam melting. 1. INTRODUCTION Conventional manufacturing is widely being used in current scenario but recently researchers and people from industry have done a lot of research and applied 3-D Printing using metals in practical applications like in the aviation industry, medical and arts. This paper is based on comparison of these two manufacturing techniques, conventional manufacturing using 4-axis CNC machine and 3-D Printing using RENISHAW AM 400; furthermore the comparison is from the manufacturing point of view only. Points of comparison consist of Lead time requirement for manufacturing, Electricity requirement for the manufacturing of same component, Total energy consumed in manufacturing of the component, steps involved in manufacturing of the same also effect of these two techniques on the environment in the form of carbon emission is presented in this study, complexity these two techniques that can handle and Mechanical testing is also added. Finite element analysis (Static) is conducted on both the parts and results. Additive manufacturing, also known as 3D printing, rapid prototyping or free form fabrication, is the process of joining materials to make objects from 3D model data, usually layer upon layer, as different to subtractive manufacturing methodologies such as machining. The use of Additive Manufacturing (AM) with metal powders is a new and growing industry sector with many of its leading companies based in Europe. developed a suitable practice to create complex metal net shape chunks, and not only prototypes, as before. Additive manufacturing now enables both a design and industrial revolution, in various industrial sectors such as aerospace, energy, automotive, medical, tooling and consumer goods D Prototyping: Selective laser sintering (SLS): In this method Additive manufacturing is carried out using laser which melts layer of build material used, the material can be either plastic, rubber, combination of both and choice of color and multicolor are also available most recent are the metals used sintered powders are available according to the application composition of powder are manufactured mainly atomization is the method of manufacturing such powders, and they are utilized in sintering type of 3D Printing. Part to be manufactured is constructed part by part by thin layers ranging from 30 micron-60 micron, as layer by layer manufacturing is carried out this gives ample of opportunity to designers for complete innovative designs such as complex hollow structures square holes etc. Volume 3 Issue 3 May

2 Flexible and rapid material changeover, Class leading patented inert atmosphere generation and low argon consumption, Open access material parameter editing, Soft re-coater blade suited to lattice and delicate geometries Build removal via chamber glove box enhances safety. 1.3 Software Details: Steps involved in additive manufacturing software: a) Orientation set the angle of the component relative to the build plate. b) Support apply sacrificial material to support the component on the build plate. c) Layout quickly organize your constituents on the construct plate to improve space. d) Portion produce the mechanism code and, directly view scan paths and exposure data. Fig1.1: Selective laser sintering (SLS) 1.4 3D MANUFACTURING: 1.2 3D Metal Printer Details: Fig No 4.1: CAD File with Supports, orientation defined. Fig 1.2: Additive Manufacturing Machine The Renishaw AM 400 includes higher safe change clean, better visual control software, revised gas flow and window protection system and a new 400 W optical system to give a reduced beam diameter of 70 μm, in line with the current AM W platform. The benefit presented by the AM 400 is the prospect to progress constraints that deliver greater production through faster scan speeds, whilst still maintaining feature definition and precision. The increased laser power of 400 W focused at 70 μm also provides the potential to process materials with elevated melting temperatures, with a significant increase in energy thickness matched to the present AM W system. Build complex metal components direct from 3D CAD data, Transferable parameters from AM W to AM 400 systems, Volume 3 Issue 3 May

3 Rapids on Z Max cutting AXIS MOTOR Max thrust X Max thrust Y Max thrust Z 1.5 Steps In Cam: 25.4 m/min 16.5 m/min METRIC N N N Step-1 Fig No 4.2: Final Product of 3D Metal Printing Process VF-2 TRAVELS METRIC (mm) X-AXIS 762 Y-AXIS 406 Z-AXIS 508 SPINDLE NOSE TO TABLE 610 (max) SPINDLE NOSE TO TABLE 102 (min) TABLE METRIC (mm) Length 914 Width 356 T-Slot width. 16 T-Slot center distance. 125 Max weight on table 1361 kg distributed. SPLINDLE METRIC (mm) Max rating 22.4 KW Max speed 8100 rpm Max torque rpm Drive system Inline direct drive Max Torque w/opt Gearbox rpm Bearing Lubrication Air/Oil injection Cooling Liquid cooled FEED RATES METRIC Rapids on X 25.4 m/min Rapids on Y 25.4 m/min CAD Model. Fig 1.5.1: Step-1Import Fig No 3.38 : Step-38 Volume 3 Issue 3 May

4 G-M codes generated in the software and complete assignment to tool is done. Final Product: Fig4.3 Modeling of conventional turbine blade using Creo 2.0 Fig No 3.39:Conventional Manufacturing 2. PROPOSED SYSTEM The turbine blade model is created by modeling in Creo 2.0 software and it is imported in to the ANSYS Workbench software. As FEA is a computer based mathematically idealized real system, which breaks geometry into element. Fig4.4 Modeling of 3D metal printing of turbine blade using Creo 2.0 It links a series of equation to each element and solves simultaneously to evaluate the behavior of the entire system. This tool is very useful for problem with complicated geometry, material properties and loading where exact and accurate analytical solution is difficult to obtain. Volume 3 Issue 3 May

5 1. Meshing Discretising of model into the small sections called as the element. Mesh element for this analysis was tetrahedron. Fig 4.5 Meshing of Conventional Turbine Blade Fig. shows the meshed model of Turbine Blade in which mesh has been selected considering the concept of grid independence. Fig 4.7 Boundary Condition for Conventional Turbine Blade Fig4.6 Mesh Model of AM Turbine Blade Loading & Boundary Conditions: 1. Fixed Support Fig 4.8 Boundary Condition for AM Turbine Blade Volume 3 Issue 3 May

6 Fig 4.11 Von misses stresses in Conventional Turbine Blade Fig shows the equivalent von-mises stress induced in master leaf under the load of 3250 N load. The maximum stress is induced near the fixed eye end of the leaf its maximum value is 400 MPa. Whereas experimentally, it is calculated as MPa. Red zone specifies the area of extreme tension and blue zone specifies the zone of least tension. Fig 4.12 Von misses stresses in AM Turbine Blade Fig shows the equivalent von-mises stress induced in master leaf under the load of 3250 N load. The maximum stress is induced near the fixed eye end of the leaf its maximum value is 400 MPa. Whereas analytically stress for this design is MPa. Red zone specifies the area of extreme tension and blue zone specifies the zone of least tension. Modal Analysis Modal analysis is approved out to conclude the usual frequencies and mode shapes of the leaf spring. Modal analysis is performed for various parametric combinations of the leaf. Modal examination necessity only edge circumstances, it is not associated with the loads apply, because natural frequencies are resulted from the free vibrations. The boundary conditions are same as in the case of static analysis. 6 number of modes are expanded. Volume 3 Issue 3 May

7 3. EXPERIMENTATION In this section the blade details and testing details of 3D Metal print turbine blade are discussed 2) Manufacturing by Conventional method has many steps, energy and time consuming and cannot handle complex manufacturing compared to 3-D Printing. 3) Material wastage in conventional manufacturing is 23.2 times more compared with Additive manufacturing. 4) Material utilization in additive manufacturing is 3.75 times more compared with conventional manufacturing. 5) CO 2 Emissions for Conventional manufacturing is 6.8 Times more as compared with 3-D Printing. 6) Energy consumption by CONVENTIONAL MANUFACTURING is 7.5 times more compared to 3-D Printing 4. RESULTS Material Used Material Wasted % Utilizati on % Wastage CONVENTIONA L MANUFACTURI NG ADDITIVE MANUFACTURI NG 515 gm 423 gm 1485 gm 14 gm CONCLUSION 1) LEAD TIME for manufacturing taken is 22 minutes less in 3-D Printing compared to conventional manufacturing. 6. REFERENCES [1] Additive Manufacturing, Cloud-Based 3D Printing and Associated Services Overview" Felix W. Baumann and Dieter Roller [2] AM 400 additive manufacturing system, Renishaw, [3] Integrated voltage current monitoring and control of gas metal arc weld magnetic ball-jointed open source 3-D printer Yuenyong Nilsiam, Amberlee S. Haselhuhn, Bas Wijnen, Paul G. Sanders,Joshua M. Pearce Michigan Technological University,2015. [4] A SCULPTEO GUIDE TO COST EFFICIENCY THROUGH SHORT SERIES MANUFACTURING: 3D PRINTING VS INJECTION MODELLING SCULPTEO, USA SCULPTEO TH STREET SAN FRANCISCO, CA 94103, FRANCE SCULPTEO 10 RUE AUGUSTE PERRET VILLEJUIF FRANCE, [5] 3D printing Conference Paper December 2014, Prepared by: Name: Samer Mukhaimar Number: Name: Saed Makhool Number: Name: Qais Samara Number: Instructor: Dr. Muhammad Abu-Khaizaran. Section: 1, Date: 12 / 11 / [6] ISSN (print) International Journal of Computer Science and Information Technology Research ISSN X (online) Vol. 2, Issue 2, pp: ( ), Month: April- June 2014, 3D Printing and Its Applications 1Siddharth Bhandari, 2B Regina 1Student, 2Assistant Professor 12 Dept. Of CSE and IT, Saveetha School of Engineering, Saveetha University, Chennai, INDIA [7] A Low-Cost Open-Source Metal 3-D Printer GERALD C. ANZALONE1, CHENLONG ZHANG1, BAS WIJNEN1, PAUL G. SANDERS1, AND JOSHUA M. PEARCE2 1Department of Materials Science and Engineering, Michigan Technological University, Houghton, MI 49931, USA 2Department of Materials Science and Engineering and the Department of Electrical and Computer Engineering, Michigan Technological University. Volume 3 Issue 3 May