This document discusses methods for reducing the stair step effect in additively manufactured surfaces. It begins with an introduction to rapid prototyping and additive manufacturing processes. It then discusses common form errors in additive manufacturing, including flatness/straightness errors, cylindricity errors, and stair step errors. The document focuses on stair step errors, explaining that they occur due to the layered manufacturing process approximating surfaces. It then discusses several methods for reducing stair step errors, including adaptive slicing to vary layer thicknesses based on geometry, and ball burnishing as a post-processing technique to smooth layer edges through plastic deformation. Finally, it discusses factors that influence the effectiveness of ball burnishing, such as ball diameter, rolling pressure, and
On July 10th Innovate UK and the KTN held a business innovation day to showcase 30 of the Innovate UK projects that are currently active in the area of Additive Manufacturing. The presentations and pitches made on the day are now available to download. Topic 3 focuses on Post Processing
University Course "Micro and nano systems" for Master Degree in Biomedical Engineering at University of Pisa. Topic: Software for additive manufacturing (part2)
Definition, need, raw materials, types of processes
Photo polymerization
Binder jetting, material extrusion
Powder bed fusion
Sheet lamination, direct energy deposition
Limitations, strengths
Programming methods.
Both traditional and modern manufacturing methods have changed the face of the manufacturing industry over the years. But which method is best for the job at hand? Here's an overview of how the most common manufacturing methods compare.
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data.Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology
Optimization of cutting strategies for forging die manufacturing on cnc milli...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
EXPERIMENTAL VERIFICATION OF HONING PROCESS PARAMETERS ON SURFACE ROUGHNESS W...IAEME Publication
Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path.
Honing is primarily used to improve the geometric form of a surface, but may also improve
the surface texture
On July 10th Innovate UK and the KTN held a business innovation day to showcase 30 of the Innovate UK projects that are currently active in the area of Additive Manufacturing. The presentations and pitches made on the day are now available to download. Topic 3 focuses on Post Processing
University Course "Micro and nano systems" for Master Degree in Biomedical Engineering at University of Pisa. Topic: Software for additive manufacturing (part2)
Definition, need, raw materials, types of processes
Photo polymerization
Binder jetting, material extrusion
Powder bed fusion
Sheet lamination, direct energy deposition
Limitations, strengths
Programming methods.
Both traditional and modern manufacturing methods have changed the face of the manufacturing industry over the years. But which method is best for the job at hand? Here's an overview of how the most common manufacturing methods compare.
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data.Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology
Optimization of cutting strategies for forging die manufacturing on cnc milli...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
EXPERIMENTAL VERIFICATION OF HONING PROCESS PARAMETERS ON SURFACE ROUGHNESS W...IAEME Publication
Honing is an abrasive machining process that produces a precision surface on a metal work piece by scrubbing an abrasive stone against it along a controlled path.
Honing is primarily used to improve the geometric form of a surface, but may also improve
the surface texture
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Here is a detailed PPT on the topic related to Basic terms of surface finish, Lay, Reasons for controlling surface roughness, factors affecting surface roughness.
EFFECT OF NOSE RADIUS ON SURFACE ROUGHNESS DURING CNC TURNING USING RESPONSE ...ijmech
The work and study presented in this paper aims to investigate the effect of nose radius on surface
roughness, in CNC turning of Aluminium (6061) in dry condition. The effect of cutting conditions (speed,
feed and depth of cut) and tool geometry (nose radius) on surface roughness were studied and analysed.
Design of Experiments (DOE) were conducted for the analysis of the influence of the turning parameter on
the surface roughness by using Response Surface Methodology (RSM) and then followed by optimization of
the results using Analysis of Variance (ANOVA) to minimize surface roughness. The nose radius was
identified as the most significant parameter. Surface roughness value decreased with increase in nose
radius.
The present work aims to investigate the distribution of strains in incremental sheet
metal forming process using different geometries. Four shapes were used to develop the
strain paths: truncated cone, pyramid, dome, and circular generatrix are formed in
incremental sheet forming process. The difference in strain paths depends on the
difference in the geometric shapes of the formed parts. Circle grid analysis was used to
obtain strain paths along the parts. Strains distribution was evaluated by circular grid
system (CGS) where a pattern of a small circle was electrochemically etched on the sheet.
The sheet is deformed during forming and the deformation of the circle is measured and
analyzed to explore the behavior of strains distribution in incremental sheet metal
forming. The curvature of the part is a large or plane wall the strain mode is plane strain
stretching and became biaxial stretching or uniaxial tension with the rotational symmetric
surfaces.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Optimization of Turning Parameters Using Taguchi MethodIJMER
Abstract: Today in manufacturing and metal industries customer satisfaction is very important to
make own place in competitive market and also to make mirror image with faith in the heart of
customer, because customer gives preference to buy good quality product. In the metal and
manufacturing industries for the product low surface roughness is very important. Lowest surface
roughness assures not only good quality but also reduces manufacturing cost. In this paper the main
objective is to study effect of cutting speed, feed rate and depth of cut on surface roughness of mild steel
in turning operation and as a result of that the combination of optimum level of factors was obtained to
get lowest surface roughness. Experiments have been conducted using Taguchi’s experimental design
technique. An orthogonal array, signal to noise ratio, and analysis of variance are employed to
investigate cutting characteristics of mild steel using high speed steel. Experimental results show that
among the cutting parameter cutting speed is the most significant machining parameter for surface
roughness followed by feed rate and depth of cut.
Experimental Investigation of Effect of Tool Length on Surface Roughness duri...IOSR Journals
: In the turning operation, vibration is a frequent problem, which affects the result of the machining
and in particular the surface finish. Tool life is also influenced by vibrations. Severe acoustic noise in the
working environment frequently results as a dynamic motion between the cutting tool and the work piece. In all
cutting operations like turning, boring and milling vibrations are induced due to deformation of the work piece.
In the turning process, the importance of machining parameter choice is increased, as it controls the surface
quality required. Tool overhang is a cutting tool parameter that has not been investigated in as much detail as
some of the better known ones. It is appropriate to keep the tool overhang as short as possible; however, a
longer tool overhang may be required depending on the geometry of the work piece and when using the holeturning
process in particular. In this study, we investigate the effects of changes in the tool overhang in the
external turning process on both the surface quality of the work piece and tool wear. For this purpose, we used
work pieces of AISI 1050 material with diameters of 20, 30, and 40 mm; and the surface roughness of the work
piece were determined through experiments using constant cutting speed and feed rates with different depth of
cuts (DOCs) and tool overhangs. We observed that the effect of the DOC on the surface roughness is negligible,
but tool overhang is more important. The deflection of the cutting tool increases with tool overhang. Two
different analytical methods were compared to determine the dependence of tool deflection on the tool
overhang. Also, the real tool deflection values were determined using a comparator. We observed that the tool
deflection values were quite compatible with the tool deflection results obtained using the second analytical
method.
Experimental Investigation and Parametric Analysis of Surface Roughness in C...IJMER
The manufacturing industries are very much concerned about the quality of their products.
They are focused on producing high quality products in time at minimum cost. Surface finish is one of the
crucial performance parameters that have to be controlled within suitable limits for a particular process.
Surface roughness of machined components has received serious attention of Researchers for many years.
It has been an important design feature and quality measure in machining process. There are a large
number of parameters which affect the surface roughness. These include cutting tool variables, work
piece material variables, cutting conditions etc. Therefore, prediction or monitoring of the surface
roughness of machined components has been challenging and unexplored area of research
The present work is therefore in a direction to integrate effect of various parameters which effect the
surface roughness. Experiments were carried out with the help of factorial method of design of
experiment (DOE) approach to study the impact of turning parameters on the roughness of turned
surfaces. A mathematical model was formulated to predict the effect of machining parameters on surface
roughness of a machined work piece. Model was validated with the experimental data and the reported
data of other researchers. Further parametric investigations were carried out to predict the effect of
various parameters on the surface research
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My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
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An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
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3. Aim- The aim of this study is to show the
general feasibility of new methods to
reduce the stair step effect of layer
manufactured surfaces.
4. INTRODUCTION
Rapid Prototyping (RP) is the process of building prototypes in slices using a layered
approach.
RP processes such as Selective Laser Sintering (SLS), Stereolithography (SLA) and 3D
Printing have been developed
RP allows prototypes with complex and intricate shapes to be built very easily. The cost
and time advantages associated has made RP extremely popular with product designers
during the early design stages.
The popularity of RP has naturally led to the extension of using additive layering
manufacturing techniques to manufacture tools, dies and industrial parts in a rapid
manner.
5. Parts created by AM have to consistently satisfy critical geometric tolerances or the parts
should be accurate.
There is a need to study RP parameters that influence tolerances on critical features of the
manufactured part. Due to the nascent stage of RM technology, the effect of the RM process
parameters on form errors has not been researched in detail.
Accuracy in additive manufacturing (AM) is evaluated by dimensional errors, form errors and
surface roughness of manufactured parts.
Types of form errors are : cylindricity errors, staircase errors & flatness errors
6. PROCESS PARAMETERS
The main process parameters in RP are :
Orientation: Orientation refers to the direction with respect to the part in which
the slices are built in the machine.
Slicing: Slicing can be performed uniformly by using slices of equal height or by
adaptive slicing using slices of unequal heights. Slicing refers to the
segmentation of the part into layers.
Supports: Supports are additional materials which are added during
manufacturing to support holes, overhangs and unsupported features.
Tool path planning: It refers to the determination of the geometric path for
building each individual layer.
7. Rapid Manufacturing (RM) processes have evolved from the Rapid Prototyping (RP) paradigm and
are increasingly being used to manufacture parts, tools and dies in addition to prototypes. The
advantages of RP methods to produce complex shapes without the use of specialized tooling can
naturally be extended to RM processes. For RM to be accepted as a mainstream manufacturing
process, parts created by RM have to consistently satisfy critical geometric tolerances
specifications for various features of the part. The process parameters, namely slice thickness,
orientation, support structures and 2D tool path planning, directly impact the final part accuracy
both individually and in combination with each other. The generation of form errors in parts
manufactured by RM depends upon the process parameters chosen by the designer during the
part build.
Form errors in layered manufacturing are:
1. Flatness & straightness errors
2. Cylindricity errors
3. Stairstep errors
8. STAIR STEP ERROR
The staircase effect has been the major concern for
industry to widely adopt rapid prototyping technologies.
It will not only worsen the surface quality but also create
errors on the parts built.AM process approximates the
object by layers with vertical edges, the stacking of the
layers does not match the original CAD model very well,
thus causing the formation of staircase-like surfaces.
The reduction of staircase effects can be categorized into
different classes contour shaping, and optimization of
the build orientation. Processes approximate objects
using layers, therefore the part being produced may
exhibit staircase effect. The extent of this staircase effect
depends on the layer thickness and the relative
orientation of the build direction and the face normal.
The minimum layer thickness for a given process is
known. Therefore for a given process, the primary factor
that determines the extent of staircase effect is the angle
between the build orientation and the face normal
9. METHODS TO REDUCE STAIR
CASE ERROR
Adaptive slicing:
the staircase effect is closely related to the layer thickness. The staircase error
increases with the layer thickness and can therefore be reduced by using thinner
layers. However, simply using thin layers will increase the number of layers and
thus the build time. A number of adaptive slicing methods have been developed
by considering the geometric features of the model, so that the error can be
reduced without a corresponding increase in the build time. An adaptive slicing
algorithm that can vary the layer thickness in relation to local geometry was
proposed.
10. Four criteria (cusp height, maximum deviation, chord length, and volumetric error
per unit length) are identified, and the layer thickness is adjusted such that one of
the four is met. Some approaches adaptively slice the STL file of a part model to
deposit a variable- layer thickness according to the geometric information extracted
from the STL file. Another class of adaptive slicing methods use the original CAD
model for the adaptive slicing and then employ piecewise-linear approximation for
the slices in that case, the surface curvature contained in the CAD model is used to
determine the slicing error .
11. Ball Burnishing
Burnishing is the plastic deformation of a surface due to sliding contact with another
object. Visually, burnishing smears the texture of a rough surface and makes it shinier.
Burnishing may occur on any sliding surface if the contact stress locally exceeds the yield
strength of the material.
It’s major function is to make parts look bright or “burnished”.
Ball burnishing is a method for post processing of surfaces. Unlike cutting processes, in
ball burnishing no material is removed. Due to a rolling contact between the roller and the
surface, plastic deformation of the surface irregularities occur which results in a
smoothing of the surface.
Therefore, ball burnishing will be used as a bulk forming operation to smooth the edges of
slicing layers. Furthermore, the influence of various ball burnishing parameters on the
surface quality will be investigated by studying of various literatures on ball burnishing
12.
13. INFLUENCE OF BURNISHING PARAMETERS
Influence of burnishing parameters
1. BALL DIAMETER: The surface flattening increases with the increase of the
ball diameter. This effect can be explained by the shape of the rolling ball. If the
diameter is small, the ball forms a groove on the surface instead of flattening.
In this case even an increase in pressure does not improve the surface
flattening. Therefore, the ball diameter must be large relative to the slicing layer
thickness to get a better surface better finishing.
2. ROLLING PRESSURE: if a ball burnishing process is applied, an increase in
the hydraulic pressure results in a better leveling of the surface. The best
average leveling is in the range of 40 mpa with a remaining unevenness of 40
%.
14. SLICING THICKNESS: The deformation required to smooth the edge of a
thinner slicing layer is less than the deformation which has to be applied
to smooth the stair steps of thicker slicing layer. Consequently, by using
the same rolling force better leveling can be achieved for thinner slicing
layer