Manufacturing Processes: Shot Peening and Casting
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Questions and Answers

Which of the following features does Magics offer?

  • Workflow Animation
  • Analyze builds (correct)
  • Image processing
  • File formats

Materialise Mimics software can create 3D anatomy models by using data from medical images.

True (A)

Name one function of the Solid Viewer software.

Markup

Velocity 2.0 helps teams keep current sprints on _____ track.

<p>track</p> Signup and view all the answers

Match the following software with their key feature:

<p>Magics = Apply textures Mimics = AI-enabled segmentation Solid Viewer = Collaboration Velocity 2.0 = Bottleneck prevention</p> Signup and view all the answers

Which feature of Mimics enhances the visualization of foreign objects?

<p>Image processing (C)</p> Signup and view all the answers

Solid Viewer software allows users to customize reports and algorithms.

<p>False (B)</p> Signup and view all the answers

What does Velocity 2.0 help teams understand regarding productivity?

<p>Productivity drivers</p> Signup and view all the answers

What is the primary purpose of shot peening?

<p>To induce compressive residual stresses (A)</p> Signup and view all the answers

Shot peening and sand blasting use the same type of particles for surface treatment.

<p>False (B)</p> Signup and view all the answers

What process creates an induced compressive stress layer to increase resistance to fatigue?

<p>Shot peening</p> Signup and view all the answers

Micro casting is also known as ______.

<p>lost-wax casting</p> Signup and view all the answers

Which of the following is NOT an application of microcasting?

<p>Clothing fabric (A)</p> Signup and view all the answers

An STL file can contain information about the texture of the 3D model.

<p>False (B)</p> Signup and view all the answers

Which material is typically used for sacrificial patterns in microcasting?

<p>Wax (B)</p> Signup and view all the answers

Match the following surface treatment processes with their characteristic features:

<p>Shot peening = Induces compressive residual stresses Sand blasting = Improves roughness and cleanliness Microcasting = Lost-wax casting method Firing = Solidifies the refractory material</p> Signup and view all the answers

What is a degenerate facet in the context of STL files?

<p>A facet where all edges are collinear.</p> Signup and view all the answers

The sacrificial models used in microcasting leave ash after burning.

<p>False (B)</p> Signup and view all the answers

A valid tessellated model must have no _____ or overlapping facets.

<p>missing facets</p> Signup and view all the answers

Match the following microcasting applications with their respective functions:

<p>Distributors = Aerodynamic applications Cork supports = Containers for storage Pump body = Construction of pumps Inverter boxes = Electromechanics</p> Signup and view all the answers

In shot peening, what happens when shots impact the surface?

<p>They generate indentations and create a compressive stressed layer.</p> Signup and view all the answers

Which type of error is caused by large curvature during tessellation?

<p>Missing facets (B)</p> Signup and view all the answers

Valid tessellated models can have multiple adjacent facets sharing the same edge.

<p>False (B)</p> Signup and view all the answers

What is one problem commonly associated with tessellation in CAD systems?

<p>Gaps or holes in the model.</p> Signup and view all the answers

What happens when a valid tessellated model is used as input?

<p>It is sliced into layers. (D)</p> Signup and view all the answers

Invalid tessellation leads to a definitive stopping boundary during the slicing process.

<p>False (B)</p> Signup and view all the answers

What is additive manufacturing (AM) software used for?

<p>To create, adapt, and manufacture 3D printed parts by providing instructions for each layer.</p> Signup and view all the answers

The software that ensures the AM process happens without errors is called ___ software.

<p>Process monitoring</p> Signup and view all the answers

Match the following AM software with their primary functionalities:

<p>CAM software = Provides instructions for producing parts layer by layer PLM software = Digitizes and controls the entire product lifecycle Slicing tool path generation = Generates G-code for printing 3D and CAT scanning software = Analyzes parts non-disruptively</p> Signup and view all the answers

Which feature is NOT associated with Materialize Magics Software?

<p>Generating G-code for printing (B)</p> Signup and view all the answers

AM software is only useful for large-scale manufacturing.

<p>False (B)</p> Signup and view all the answers

Name one feature of CAM software.

<p>Provides instructions for producing parts layer by layer.</p> Signup and view all the answers

Flashcards

Shot peening process

A cold work process that adds compressive residual stresses to a component's surface, improving its mechanical properties.

Shot peening vs. Sand blasting

Both are surface treatments, but shot peening uses round particles (metal, glass or ceramic) with higher impact and resulting higher surface roughness to induce compressive stresses; sand blasting uses sand particles creating lower surface roughness.

Sacrificial patterns

Wax or other material forms of a component made for the purpose of creating a mold in microcasting.

Microcasting

A casting technique using wax patterns to create intricate part geometries, then dissolving the wax and replacing it with molten metal.

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Compressive residual stress

Internal stress in the surface of a material that is directed inwards, increasing fatigue resistance and reducing stress concentration.

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Fatigue resistance

A material's ability to withstand repeated stress cycles without failure.

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Lost-wax casting

A type of casting where a wax model is used as a pattern to create a cavity in a molding material, then the molten metal is poured into this cavity to solidify into the desired shape

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Microcasting applications

Microcasting is used for producing complex shapes and high precision parts, often for intricate mechanical components and components in very small devices.

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STL file format

A file format used in 3D printing and CAD, representing 3D objects as an unordered list of triangles (facets), lacking color or texture.

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STL file problem: Gaps

Gaps, holes, or cracks in the 3D model, resulting from inaccuracies in tessellation algorithm (creating triangular facets).

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STL file problem: Degenerate facets

Facets where all edges are collinear (in a straight line), a geometrical error in tessellation.

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STL file problem: Overlapping facets

Facets that unintentionally overlap each other, a problem in a tessellated model from the tessellation algorithm.

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Valid STL Model

A 3D model without gaps or any errors in the tessellation process, such that each facet has only one edge shared by two facets.

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Applications of microcasting

Various uses, including molds for breads, parts for cars and engines, electronic equipment, industrial components and more.

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Tessellated Model

A 3D model represented as a mesh of connected polygons, used for 3D printing.

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Slicing (AM)

The process of dividing a 3D model into thin layers, preparing it for 3D printing.

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Unidirectional Scan Lines

Lines traced by a 3D printer's nozzle, creating a single layer of the object.

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AM Software

Software used for designing, preparing, and controlling 3D printing processes.

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CAM Software

AM software that generates instructions for layer-by-layer production of 3D prints.

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Process Monitoring Software

AM software that checks for errors and ensures a smooth 3D printing process.

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MES Software

AM software that manages the entire 3D printing process, from order to delivery.

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PLM Software

AM software that tracks the entire lifecycle of a 3D printed product, from design to disposal.

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Magics software

A 3D printing software used for various tasks like arranging parts efficiently, analyzing potential issues, and estimating build times.

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Nest parts

Magics can arrange multiple 3D printing parts in the smallest possible area on the build platform, minimizing wasted space.

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Analyze builds

Magics can identify potential issues with a 3D model before printing, such as weak points or unsupported sections, preventing failed prints.

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Build time estimation

Magics can estimate how long it will take to print a 3D model, helping you plan your printing time.

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Apply textures

Magics allows you to apply textures, graphics, and visual effects to specific surfaces of a 3D model, adding detail and realism.

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Mimics software

A software specifically designed for creating, analyzing, and printing 3D medical models using segmented medical images.

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3D modelling (Mimics)

Mimics software can create 3D anatomical models by segmenting medical images (like CT scans), providing detailed anatomical information.

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AI-enabled segmentation (Mimics)

Mimics uses artificial intelligence to automatically identify and separate different tissues and structures in medical scans, making analysis faster and more accurate.

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Study Notes

Assignment 03

  • Shot peening: A cold work process used to impart compressive residual stresses on a component's surface, modifying its mechanical properties and reducing stress profiles.

  • How shot peening works: Impacted by shot (metal, glass, or ceramic particles), the surface experiences plastic deformation, generating multiple indentations leading to a compressive stressed layer on the metal surface.

Shot Peening vs. Sand Blasting

  • Shot peening: Imparts compressive stresses, leading to increased strength and resistance to fatigue, stress corrosion, and cavitation erosion.
  • Sand blasting: Improves surface roughness and cleanliness.

Microcasting (Lost-Wax Casting)

  • Definition: A casting process using sacrificial patterns identical to the part's geometry, made of materials that liquefy and burn away, leaving no ash.

  • Application: Used to create complex shapes, especially for small parts and intricate geometries.

  • Process: Creating patterns and embedding them in an inert material (e.g., plaster, liquid ceramic), allowing for the molten metal to occupy the cast spaces to create the finished component.

Selective Laser Sintering (SLS)

  • Working Principle: A powder bed is selectively melted using a focused laser beam, building layers one on top of the other to create the final solid part.

  • Advantages: No part supports required which saves time, and little post-processing needed, good part stability.

Laser Engineered Net Shaping (LENS)

  • Working principle: Similar to SLS, but the powder is injected by a nozzle, creating the final component.

  • Advantages: Wide range of processing materials, little post-processing required, no part supports required.

  • Disadvantages: Large physical size of the unit, high power consumption, high cost.

Electron Beam Based Powder Bed

  • Working Principle: A focused beam of electrons is used to melt or sinter metal powder (similar to Laser Sintering).

  • Advantages: High precision, superior material properties, high energy efficiency, fast build rates.

  • Disadvantages: Complex setups, high power consumption.

STL File Format

  • Definition: A file format used widely in 3D printing and CAD, consisting of an unordered list of triangular facets representing the outside surface of an object, without color, texture or other attributes.

  • Problems: Missing facets/gaps, overlapping facets and/or non-manifold topology conditions leading to faulty geometries causing problematic prints. Often results in an approximate rather than precise model.

  • Valid STL Model: No missing facets, overlapping facets or degeneracies.

  • Invalid STL Model: Presence of missing facets, overlapping facets or any other abnormalities such as geometrical degeneracies that will cause mistakes on construction.

AM Software

  • Importance: Essential for managing the entire additive manufacturing process, ensuring the process happens without errors and coordinating the entire product's lifecycle.

  • CAM software: Provides instructions for building parts, layer by layer.

  • Process monitoring software: Ensures the AM process runs accurately without errors.

  • MES software: Controls and coordinates the product lifecycle from quotation to final use

  • PLM software: Digitizes and controls the entire product lifecycle.

  • 3D and CAT scanning software: Analyses parts non-destructively.

  • Part finishing software: Software that uses appropriate methods for accurate 3D product design.

  • Slicing tool path generation software: Generates g-code to control the 3D printer.

  • Printer interface software: Provides essential information about material levels, print status, error notifications, and more.

  • Feature examples: MAGICS (file editor and preparation), MIMICS (medical image processing), and SOLID VIEWER (viewing, sharing and collaboration software), and Velocity 2.0 (managing project sprints for consistent productivity).

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Assignment 03 PDF

Description

This quiz explores key manufacturing processes such as shot peening and microcasting. Understand how shot peening imparts compressive stress to enhance mechanical properties and contrast it with sand blasting. Additionally, dive into the intricacies of lost-wax casting for creating complex shapes.

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