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    MSIE 12 T M1S1 Le01

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    MSIE 12 T M1S1 Le01

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    Mayank
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    1.-MSIE-12-T-M1S1-Le01

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    3 views22 pages

    MSIE 12 T M1S1 Le01

    Uploaded by

    Mayank

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 22

    Course 12: Additive Manufacturing for Industry 4.

    Lecture 1 – Teaching material (T)

    Developer: Pisut Koomsap

    Curriculum Development

    of Master’s Degree Program in

    Industrial Engineering for Thailand Sustainable Smart Industry


    P. Koomsap
    1. Additive Manufacturing Basic Concepts and processes

    • Additive Manufacturing workflow


    • Benefits & Limitations of Additive Manufacturing
    • Applications of 3D printing (Aerospace, Automotive, Robotics,
    Tooling, Healthcare,
    • Design, Education etc.)
    • Main technologies (ISO/ ASTM DIS 52900:2018)
    Textbooks
    C K Chua, K F Leong, and C.S. Lim, Rapid Prototyping: Principles and
    Applications, 2nd Edition, World Scientific, 2003
    K.G Cooper, Rapid Prototyping Technology: Selection and Application,
    Marcel Dekker, 2001
    P.D Hilton, and P.F. Jacobs, Rapid tooling : technologies and industrial
    applications, Marcel Dekker, 2000
    W.M. Steen, Laser Material Processing, 2nd Edition, Springer, 1998
    Prototyping

    A process of developing an approximation of the


    product along one or more dimensions of interest

    Purposes of Using Prototypes


    • Learning: Will it work?
    • Communication: Look&Feel
    • Integration: Components work together
    • Milestones: Achievement
    Types of Prototypes

    •The degree to which they are physical


    • Physical Prototypes
    • Analytical Prototypes

    • The degree to which they implement the


    products’ attributes
    • Comprehensive Prototypes
    • Focused Prototypes
    Physical

    Final Product
    Beta Prototype
    Part Prototype Alpha Prototype

    Focused Comprehensive
    Simulation

    Not generally
    feasible
    Equation Modeling

    Analytical
    Appropriateness of Different Types of Prototypes
    for Different Purposes

    Communi
    Types of Prototypes Learning Integration Milestones
    cation

    Focused Analytical

    Focused Physical

    Comprehensive
    Physical
    Principles of Prototyping

    • Analytical prototypes are generally more flexible


    than physical prototypes
    • Physical prototypes are required to detect
    unanticipated phenomena
    • A prototype may reduce the risk of costly iterations
    • A prototype may expedite other development steps
    • A prototype may restructure task dependencies
    Planning for Prototypes

    1. Define the purpose of the prototype


    2. Establish the level of approximation
    of the prototype
    3. Outline the experimental plan
    4. Create a schedule for procurement,
    construction, and test
    Prototype
    Subtractive Additive Fabrication
    SLA,
    Techniques
    Laser Cutting
    Waterjet Cutting SLS,
    LOM FDM,
    EDM
    EB Direct Casting
    CNC machining

    Laser
    Bending

    Electromagnetic Forming,
    Adaptive Die Casting,
    Casting,
    Forging

    Formative
    Prototyping Manual Virtual Rapid

    RP SLA FDM
    Techniques LOM
    SLS

    NC Laser RP
    Technology PC
    CNC Robot
    CAD
    1940

    1950

    1960

    1970

    1980

    2000
    1990
    What is Additive Manufacturing?

    • Additive Manufacturing is a method in which the part is created


    by a layer- additive process.
    • Using a specialized software, a 3-D CAD model is cut into very
    thin layers or cross-sections.
    • Then, depending on the specific method used (sintering, fused
    deposition, etc), the AM machine constructs the part layer by
    layer until a solid replica of the CAD model is generated.
    • The advantages of this process is clear: development of
    physical models can be accomplished in significantly less time
    as compared to the machining process.

    http://www.caip.rutgers.edu/RP_Library/process.html
    Commonly Used Terms for Additive Manufacturing

    • Rapid Prototyping (RP)


    • Direct CAD Manufacturing
    • Desktop Manufacturing
    • Instant Manufacturing
    • CAD Oriented Manufacturing
    • Layer Manufacturing
    • Material Deposit Manufacturing
    • Material Addition Manufacturing
    • Solid Freeforming
    Why Rapid Prototyping?

    Machining is a subtractive process, beginning with a solid piece


    of stock. The machinist must carefully remove material until the
    desired geometry is achieved. For complex part geometries,
    this is an exhaustive, time consuming, and expensive process.
    Some parts are even too complex to be machined.

    http://www.caip.rutgers.edu/RP_Library/process.html
    AM for Product Development Process

    Concept System-Level Detail Testing & Production


    Development Design Design Refinement Ramp-Up

    Concept System-Level Detail Testing & Production


    Development Design Design Refinement Ramp-Up
    Input Material
    Paper, Resins, Nylon, ABS,
    • Physical Objects Wax, metals, ceramics
    • CAD Models •Liquid
    • STL Files •Powder
    • Sliced Model Files •Solid

    RP

    Method Applications

    • Design
    • Photocuring
    •Engineering, Analysis&Planning
    • Cutting&Gluing
    •Manufacturing&Tooling
    • Melting&Solidifying
    • Binding
    Basic Steps of AM Processes
    Computed Tomography Create a CAD model of the design
    Scan

    Convert the CAD model to


    STL format

    Slice the STL file into layers

    • RP requires a closed
    volume of the model Construct the physical model
    • What you see may layer by layer
    not be what you get
    Clean and finish the model

    The tessellated model


    Advantages of AM

    • Reduce product development time and cost


    • Get products to market sooner
    • Enhance communications between marketing,
    engineering, manufacturing, and purchasing
    • Present physical model at critical design reviews
    • Perform functional prototype testing before
    committing to tooling
    • Generate precise production tooling
    Issues in Layered-Based Manufacturing

    • Staircase effect
    • Layer thickness
    • Accuracy
    • Part orientation
    • Support Structures
    AM Processes

    Material Basic Process Process Name

    Gluing Sheets Laminated Object Manufacturing


    (LOM)
    Solid
    Melting+Solidification Fused Deposition Manufacturing
    (FDM)

    Material powder Selective Laser Sintering


    (SLS)
    Powder
    Material+Binder 3D Printing

    Solid Ground Curing


    Liquid
    (SGC)
    Liquid Polymerization
    Stereolithography
    (SLA)

    Steen, Laser Material Processing


    Applications of AM

    Design
    • CAD model verification
    • Visualizing objects
    • Proof of concept
    • Market and presentation application

    Engineering Analysis and Planning


    • Form and fit
    • Stress analysis
    • Mock-up parts
    • Pre-production parts
    • Diagnostic and surgical operation planning
    Applications of AM

    Manufacturing and Tooling


    • Tooling mold parts (soft tooling and hard tooling)
    • Casting
    • EDM electrodes
    • Master models
    Industries
    • Aerospace
    • Jewelry
    • Consumer electronics
    • Automotive
    • Biomedical
    • Tableware

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