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Unit 1 Add Mfg.pptx
- 1. Additive Manufacturing Dr. Sagar Dhage
- 2. Course Objectives: • The students will possess the required knowledge and skills to manufacture components using additive manufacturing processes. • To know the principles, methods, possibilities, and limitations as well as environmental effects of Additive Manufacturing technologies. • To be familiar with the characteristics of the different materials that are used in Additive Manufacturing technologies.
- 3. Course Outcomes CO 1. Understand the working principles and process parameters of additive manufacturing processes. CO 2. Explore different additive manufacturing processes and suggest suitable methods for building a particular component CO 3. Perform suitable post-processing operation based on product repair requirement CO 4. Design and develop a working model using additive manufacturing Processes CO 5. Understand the concept of post-processing on additive manufacturing CO 6. Emphasize the fundamentals of process selection
- 4. Course Content • Unit 1:INTRODUCTION TO ADDITIVE MANUFACTURING • Unit 2: VAT PHOTOPOLYMERIZATION AND MATERIAL JETTING AM PROCESSES • Unit 3: SHEET LAMINATION AND POWDER BED FUSION AM PROCESS • Unit 4: DIRECTED ENERGY DEPOSITION AND WIRE ARC ADDITIVE MANUFACTURING PROCESSES • Unit 5: MATERIALS SCIENCE AND POST PROCESSING OF AM PARTS • Unit 6: GUIDELINES FOR PROCESS SELECTION
- 5. Rules • Readymade notes will not be provided. • PPT presented in the class shall be uploaded on Moodle. • Questions in the examination based on Class PPT and Assignment • Assignment on each Unit. • No entry I class for late comers.
- 7. Unit 1: INTRODUCTION TO ADDITIVE MANUFACTURING Introduction to AM, AM evolution, Distinction between AM & CNC machining, Steps in AM, Classification of AM processes, Advantages of AM and Types of materials for AM
- 8. What is Manufacturing? Definition: 15th century manus : hand factus : make Definition by S.Kalpakjian, S.R. Schmid Raw materials Product Process i. Design of product ii. Raw materials selection iii. Sequence of process in manufacture product
- 9. What is Manufacturing? Definition by Mikell P. Groover: a) Technologically b) Economically
- 10. Types of Manufacturing? 1. Formative Manufacturing 2. Subtractive Manufacturing 3. Additive Manufacturing
- 11. Types of Manufacturing? 1. Formative Manufacturing • Formative manufacturing typically forms material into the desired shape via heat and pressure • Injection molding, casting, stamping and forging • Image source: Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, MP Groover, edition 5. Casting Process Forging Process
- 12. Types of Manufacturing? 2. Subtractive Manufacturing • Utilizes cutting tools to remove the unwanted material to get final shape • Turning, milling, drilling etc • Image source: www.sandvik.coromant.com Turning Milling
- 13. Types of Manufacturing? 3. Additive Manufacturing • Building part layer by layer Source: HASBRO/MB Puzzle Principle of layer technology, example: sculpture puzzle
- 14. Types of Manufacturing? 3. Additive Manufacturing • Building part layer by layer Source: www.sulzer.com
- 15. Types of Manufacturing? 3. Additive Manufacturing (AM) Building up the part layer by layer • A process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies [1]. [1] ISO/ASTM 52900:2015 Standard Terminology for Additive Manufacturing Technologies CAD File Slicing 3D Printing Final physical object
- 16. Types of Manufacturing? 3. Additive Manufacturing (AM) Building up the part layer by layer • A process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies [1]. [1] ISO/ASTM 52900:2015 Standard Terminology for Additive Manufacturing Technologies
- 18. 3D bioprinted trachea model (Image courtesy of United Therapeutics)
- 19. Distinction between AM & CNC machining
- 20. Distinction between AM & CNC machining • Gibson, I., Rosen, D., and Stucker, B., 2015, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, Springer New York, New York, NY
- 21. Distinction between AM & CNC machining • Gibson, I., Rosen, D., and Stucker, B., 2015, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, Springer New York, New York, NY
- 22. Distinction between AM & CNC machining • Materials • Speed • Ease of use • Accuracy, Size limitations & Geometric Complexity • Programming • Cost • Environmentally Friendly
- 23. • 3D Printing—the fabrication of objects through the deposition of a material using a print head, nozzle, or another printer technology. • Additive manufacturing (AM)—a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. • Rapid prototyping—additive manufacturing of a design, often iterative, for form, fit, or functional testing, or combination thereof ISO/ASTM 52900:2015 (E), Standard Terminology for Additive Manufacturing-General Principles Terminology
- 25. Comparison : Traditional Mfg vs AM Busachi, A., Erkoyuncu, J., Colegrove, P., Martina, F., Watts, C., and Drake, R., 2017, “A Review of Additive Manufacturing Technology and Cost Estimation Techniques for the Defence Sector,” CIRP J. Manuf. Sci. Technol., 19, pp. 117–128. Hopkinson, N., and Dicknes, P., 2003, “Analysis of Rapid Manufacturing—Using Layer Manufacturing Processes for Production,” Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci., 217(1), pp. 31–39. Fig. AM Complexity for Free Fig. AM Economies of Scale
- 26. Comparison : Traditional Mfg vs AM • AM advantages • Rapid prototyping • Design freedom • Customisation • Low volume production • Less inventory Busachi, A., Erkoyuncu, J., Colegrove, P., Martina, F., Watts, C., and Drake, R., 2017, “A Review of Additive Manufacturing Technology and Cost Estimation Techniques for the Defence Sector,” CIRP J. Manuf. Sci. Technol., 19, pp. 117–128. Hopkinson, N., and Dicknes, P., 2003, “Analysis of Rapid Manufacturing—Using Layer Manufacturing Processes for Production,” Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci., 217(1), pp. 31–39. Fig. AM Complexity for Free
- 27. Comparison : Traditional Mfg vs AM • AM Limitations • High Production cost • Mechanical Properties • Requires post processing • Limited build size • Stair stepping effect M. Pérez, A. García-Collado, D. Carou, G. Medina-Sánchez, R. Dorado-Vicente,Chapter 11 - On surface quality of engineered parts manufactured by additive manufacturing and postfinishing by machining, Editor(s): Juan Pou, Antonio Riveiro, J. Paulo Davim, In Handbooks in Advanced Manufacturing, Additive Manufacturing,Elsevier,2021, Stair stepping effect
- 29. Evolution of AM Blanther JE (1892) Manufacture of Contour Relief Maps, US Patent 473,901. • Prehistory Fig. The images are a topographical map showing iso-elevation lines (left) and a wax toolset and moulded paper 3D map (right) obtained by a cut-and-stack approach Blanther layered manufacturing, 1890s Raised relief map
- 30. Evolution of AM Baker R (1925) Method of Making Decorative Articles. US Patent 1,533,300 • Prehistory Fig. Weld overlay to create three-dimensional objects Ralf Baker’s Invention-1920 Utilised electric arc welding
- 31. Evolution of AM Ciraud PA (1972) Process and Device for the Manufacture of any Objects Desired from any Meltable Material, FRG Disclosure Publication: 2663777. • Precursors Fig. Embodiment of additive manufacturing dated 1972. Metal powder (2) delivery into an energy source/s (7/7a) to create a part (15) built from a baseplate Pierre Ciraud’s Invention: 1971 • Concept of Directed Energy Deposition • Method for manufacturing articles of any geometry by applying powdered material • A Laser, Electron Beam or Plasma Beam then heats the particles locally
- 32. Evolution of AM • Precursors Ross Housholder’s Invention: 1979 • Laser Sintering: Selectively scanning a powder bed surface with a laser beam. • Use of Computer for laser process controlling Housholder, R. F., 1996, “Molding Process.”
- 33. Evolution of AM Deckard, C. R., 1989, “Method and Apparatus for Producing Parts by Selective Sintering.” • Beginning of Modern AM Technology Carl R. Deckard’s Invention: 1986-90 • Invented Selective laser Sintering (SLS) • Selectively sintering a layer of powder to produce a part comprising a many of sintered layers. • Computer controlling a laser to direct the laser energy
- 34. Evolution of AM • Beginning of Modern AM Technology Charls Hull’s Invention: 1984-1990 • Invented Stereolithography • Commercialised by 3D system • A Fluid medium capable of solidification when exposed to UV light • Use of CAD model Hull, C., 1984, “Apparatus for production of three-dimensional objects by stereolithography.”
- 35. Evolution of AM • Beginning of Modern AM Technology Scott Crump 1989 • Invented Fused Deposition Modelling • Founder of Stratasys FDM is the most commonly used 3D printing technique today, works by heating and extruding thermoplastic filament, depositing layers of semi-liquid beads along an STL-defined extrusion path. Scott Crump
- 36. Evolution of AM • Beginning of Modern AM Technology Crump, S. S., 1992, “Apparatus and Method for Creating Three-Dimensional Objects.” Scott Crump 1989
- 37. Evolution of AM • Beginning of Modern AM Technology Source: youtube.com Scott Crump 1989
- 38. Evolution of AM • Beginning of Modern AM Technology Sachs et al.- 1989 Sachs, E. M., Haggerty, J. S., Cima, M. J., and Williams, P. A., 1993, “Three-Dimensional Printing Techniques.” • Invented Binder Jetting • liquid bonding agent is selectively deposited to join powder materials • Term 3D printing was introduced
- 39. Evolution of AM • Beginning of Modern AM Technology Hanan Gothait - 1999 • Invented Material Jetting • Droplets of build material are selectively deposited • Example materials include photopolymer and wax. • Patent expired in 2019 Gothait, H., 2001, “Apparatus and Method for Three Dimensional Model Printing.”
- 40. Evolution of AM Object created without layer wise fashion without part specific tooling and without use of computer Prehistory Computer used to fabricate but no commercialization Precursor Commercialization Modern Technology Mid 1860 1968-1985 1985-Present
- 41. 3D CAD Model Layer Operation Powder Wire Liquid Sheets Physical object Working Principle of AM Fig. Schematic of the working principle of AM
- 42. 3D CAD Model Layer Operation Powder Wire Liquid Sheets Physical object Commercial AM Fig. Schematic of the working principle of AM
- 43. The Generic AM Process Steps • Gibson, I., Rosen, D., and Stucker, B., 2015, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, Springer New York, New York, NY.
- 44. The Generic AM Process Steps • Post Processing • Removal of support structure • https://i.materialise.com/blog/en/remove-support-3d-prints/
- 45. Additive Manufacturing Process Categories as per ASTM standard F2792 1. Binder jetting 2. Directed Energy Deposition 3. Material Extrusion 4. Material Jetting 5. Powder Bed Fusion 6. Sheet Lamination 7. Vat Photopolymerization ISO/ASTM 52900:2015 (E), Standard Terminology for Additive Manufacturing-General Principles Terminology
Editor's Notes
- As a noun, the word manufacture first appeared in English around 1567 A.D. As a verb, it first appeared around 1683 A.D.
- Technologically, manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/ or appearance of a given starting material to make parts or products; manufacturing also includes assembly of multiple parts to make products. Economically, manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations. The key point is that manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials that have been similarly altered.
- Formative manufacturing typically forms material into the desired shape via heat and pressure. The raw material can be melted down and extruded under pressure into a mold (injection molding/die casting), melted and then poured into a mold (casting) or pressed .
- Formative manufacturing typically forms material into the desired shape via heat and pressure. The raw material can be melted down and extruded under pressure into a mold (injection molding/die casting), melted and then poured into a mold (casting) or pressed .
- It shows the so-called sculpture puzzle, in which a three-dimensional (3D) object has to be assembled from more than 100 slices. Therefore the layers have to be arranged vertically in the right sequence using a supporting stick. Additive manufacturing (AM) is an automated fabrication process based on layer technology. AM integrates two main subprocesses: the physical making of each single layer and the joining of subsequent layers in sequence to form the part. Both processes are done simultaneously. The AM build process just requires the 3D data of the part, commonly called the virtual product model.
- AM refers to a broad family of techniques that turn 3D digital designs into actual functional parts in the same way an office printer places two dimensional (2D) digital files onto pieces of paper. ASTM defines Am as …
- Compared to traditional manufacturing methods, AM does not benefit from economies of scale. This is due to two main constraints, slow deposition rates and limited built capacity. AM is considered a more suitable technology for economically sustainable small to medium volume productions. Moreover the technology allows design complexity for free. In traditional manufacturing methods, high level of customization might result in prohibitive manufacturing costs. This is due to high investment in modifications of the manufacturing line. This suggests that AM might have a higher product cost compared to traditional methods but if positioned correctly, the technology might give strategic advantages.
- Two prehistorical approaches for production of metal parts involve sheet lamination and weld deposition . Blanther suggested a layered method for making a mold for topographical relief maps. The method consisted of impressing topographical contour lines on a series of wax plates and cutting these wax plates on these lines. After stacking and smoothing these wax sections, one obtains both a positive and negative three-dimensional surface that corresponds to the terrain indicated by the contour lines. After suitable backing of these surfaces, a paper map is then pressed between the positive and negative forms to create a raised relief map. Sheet lamination of non-metallic feedstock developed over the next sixty years .
- The use of a moving weld head to build up objects was initially patented by Baker in 1925 [20]. Fig. 3 illustrates a sketch from the patent.
- In 1971 the Frenchman Pierre Ciraud filed a patent application describing a method for manufacturing articles of any geometry by applying powdered material, e.g. metal powder, onto a substrate and solidifying it by means of a beam of energy, e.g. a laser beam. To produce an object, small particles are applied to a matrix by gravity, magnetostatics, electrostatics, or positioned by a nozzle located near the matrix. A Laser, Electron Beam or Plasma Beam then heats the particles locally. As a consequence of this heating, the particles adhere to each other to form a continuous layer
- Step 1: CAD All AM parts must start from a software model that fully describes the external geometry Step 2: Conversion to STL Nearly every AM machine accepts the STL file format, which has become a de facto standard, and nowadays nearly every CAD system can output such a file format. This file describes the external closed surfaces of the original CAD model and forms the basis for calculation of the slices. Step 3:Transfer to AM Machine and STL File Manipulation The STL file describing the part must be transferred to the AM machine. Here, there may be some general manipulation of the file so that it is the correct size, position, and orientation for building Step 4:Machine Setup The AM machine must be properly set up prior to the build process. Such settings would relate to the build parameters like the material constraints, energy source, layer thickness, timings, etc. Step 5: Build Building the part is mainly an automated process and the machine can largely carry on without supervision. Only superficial monitoring of the machine needs to take place at this time to ensure no errors have taken place like running out of material, power or software glitches, etc Step 6: Step 6: Removal Once the AM machine has completed the build, the parts must be removed Step 7: Step 7: Post-processing Once removed from the machine, parts may require an amount of additional cleaning up before they are ready for use. Parts may be weak at this stage or they may have supporting features that must be removed. This therefore often requires time and careful, experienced manual manipulation