Chapter 2 Development of AM Technology PDF

Chapter 2 Development of AM Technology  Development of AM Technology Objectives: – Discuss on: Additive manufacturing technology Computers – Processing power; Graphical capability; Machine Control; Networking; and Integration Computer-aided design t...

Chapter 2 Development of AM Technology  Development of AM Technology Objectives: – Discuss on: Additive manufacturing technology Computers – Processing power; Graphical capability; Machine Control; Networking; and Integration Computer-aided design technology – CAD; 3D solid modeling; CAM; NC technologies; CAE; FEA; and Non-Uniform Rational Basis-Splines (NURBS) – CAD technology: Improved along – Realism; Usability and user interface; Engineering content; Speed; Accuracy; Complexity; and Usability Other associated technologies – Lasers; Printing technologies; Programmable logic controllers (PLCs); Materials; and CNC machining The use of layers Classification of AM processes – Liquid polymer systems; Discrete particle systems; Molten material systems; Solid sheet systems; and New AM classification schemes Development of AM Technology Metal systems Hybrid systems Milestones in AM development AM around the world The future? Rapid prototyping develops into direct digital manufacturing Assignment: – Read Chapter 2, Pages 19 - 42 Homework: – Exercises: 1-6 YouTube Videos Vat Polymerisation https://www.youtube.com/watch?v=g3OUWihMWIQ Stereolithography Process https://www.youtube.com/watch?v=WqSqUFp8D3I Stereolithography (SLA) 3D Printing Process by 3D Systems https://www.youtube.com/watch?v=yYGycgnYlBM Powder Bed Fusion https://www.youtube.com/watch?v=CFXLoJlTRIU  Introduction Introduction – AM Technology – Computer-Aided Design (CAD) Computers – Serviceable tools and their ability to perform tasks in real-time – AM takes full advantage of important features of computer technology both directly (in the AM machines) and indirectly (within the supporting technology): Processing power Graphics capability Machine control Networking Integration Computer-Aided Design Technology 3D Solid-Modeling CAD software Layer–Based AM technology Computer-Aided Manufacturing (CAM): NC & CNC machines – Almost every part is made in stages, often requiring multiple passes for material removal and setups – All machining is performed from an approach direction (sometimes referred to as 2.5D rather than fully 3D manufacture). This requires that the stock material is held in a particular orientation and that not all the material can be accessible at any one stage in the process. Computer-Aided Engineering Finite Element Analysis (FEM)  Computer-Aided Design Technology CAD Technology: Rapidly improved along the following lines: – Realism – Usability and user interface – Engineering content – Speed – Accuracy – Complexity – Usability AM Technology – STL File Format Uses triangles to describe the surface to be built Each triangle is described as three points and a facet normal vector indicating the outward side of the triangle  Other Associated Technologies Other Associated Technologies – Lasers – Printing Technologies – Programmable Logic Controllers – Materials – Computer Numerically Controlled (CNC) Machining The use of Layers Classification of AM Processes – Liquid Polymer Systems – Discrete Particle Systems – Molten Metal Systems – Solid Sheet Systems  Classification of AM Processes New AM Classification Schemes: Seven Process Categories – Vat photopolymerization: processes that utilize a liquid photopolymer that is contained in vat and processed by selectively delivering energy to cure specific regions of a part cross-section – Powder bed fusion: processes that utilize a container filled with powder that is processed selectively using an energy source, most commonly a scanning laser or electron beam – Material extrusion: processes that deposit a material by extruding it through a nozzle, typically while scanning the nozzle in a pattern that produces a part cross-section – Material jetting: ink-jet printing processes – Binder jetting: processes where a binder is printed into a powder bed in order to form part cross-section – Sheet lamination: processes that deposit a layer of material at a time, where the material is in sheet form – Directed energy deposition: processes that simultaneously deposit a material (usually powder or wire) and provide energy to process that material through a single deposition device  Future of Additive Manufacturing Metal Systems: – Laser-Engineered Net Shaping (LENS), Electron Beam Melting (EBM) Hybrid Systems – Shaped Deposition Manufacturing (SDM) Milestones in AM Development – Laminated Object Manufacturing, 3D printing, SLS, FDM AM Around the World – Early patents: Europe (France), USA, Asia (Japan) – Companies from Germany, Netherland, Sweden – Korea and China – Israel (Cubital) Future – Rapid prototyping develops into direct digital manufacturing RM: Rapid Manufacturing DDM: Direct Digital Manufacturing  Exercises 1. a. Based on the internet search, describe the Solid Ground Curing process developed by Cubital. b. Solid Ground Curing has been described as a 2D channel (layer) technique. Could it also be described in another category? Why? 2. Make a list of different metal AM technologies that are currently available on the market today. How can you distinguish between the different systems? What different materials can be processed in these machines? 3. NC machining is often referred to as 2.5D process. What does this mean? Why might it not be considered as fully 3D? 4. Provide three instances where a layer-based approach has been used in fabrication, other than AM. 5. Find five countries where AM technology has been developed commercially and describe the machines. 6. Consider what a fabrication system in the home might look like, with the ability to manufacture many of the products around the house. How do you think this could be implemented?