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Am Unit 1

The document outlines the fundamentals and applications of Additive Manufacturing (AM) in engineering design, emphasizing the importance of prototypes in product development. It discusses the historical development of Rapid Prototyping (RP) technologies, the phases of prototyping, and the advantages of RP systems. Additionally, it categorizes RP systems into liquid-based, solid-based, and powder-based, and highlights the distinctions between AM and CNC machining.

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16 views34 pages

Am Unit 1

The document outlines the fundamentals and applications of Additive Manufacturing (AM) in engineering design, emphasizing the importance of prototypes in product development. It discusses the historical development of Rapid Prototyping (RP) technologies, the phases of prototyping, and the advantages of RP systems. Additionally, it categorizes RP systems into liquid-based, solid-based, and powder-based, and highlights the distinctions between AM and CNC machining.

Uploaded by

228w1a0492
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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ADDITIVE

MANUFACTURING
(20ME6205 B )
CO1: Recognize the importance and
application of AM models in engineering
design.
CO2: Develop various layered models using
different AM methods.
CO3: Illustrate the methodology to manipulate
the STL file for improved part accuracy.
CO4:Understand the applications of AM
UNIT 1
 Introduction: Additive Manufacturing, AM Parts
Used, Generic AM Process, Distinction between
AM and CNC Machining, Prototype
Fundamentals, Historical Development,
Fundamentals of RP, Advantages of RP,
Classification of RP processes, Steps in AM
process Chain.
INTRODUCTION
 The Competition in the world market for
manufactured products has intensified
tremendously in recent years.
 It has become important for new products to reach
the market as early as possible, before the
competitors.
 In product development, time pressure has been a
major factor in determining the direction and
success of developing new methods and advanced
technologies.
Cont.…
 Definition of a prototype:

A prototype is an important and part of the


product development process.
 In any design practice, the word “prototype” is
often not far from the things that the designers
will be involved in.
PROTOTYPE
A Prototype is the first or original example of
something that has been or will be copied or
developed: it is a model or preliminary version:

e.g: A Prototype supersonic aircraft


“ An approximation of a product (or system) or its
components in some form for a definite purpose
in its implementation”.
Types of Prototypes
 The implementation of the prototype; from the
entire product(or system) itself to its subassemblies
and components.
 The form of the prototype; from a virtual prototype
to a physical prototype.
 The degree of the approximation of the prototype;
from very rough representation to exact replication
of the product.
Roles of the Prototypes
 Experimentation and learning

 Testing and proofing

 Communication and interaction

 Synthesis and integration

 Scheduling and markers


Cont.…
 To the product development team, prototypes can be
used to help the thinking, planning, experimenting and
learning processes whilst designing the product.
 The prototype also serves the purpose of
communicating information and demonstrating ideas,
not just within the product development team, but also
to the management and clients.
Cont.…
 The development of RP is closely tied in with the
development of applications of computers in the
industry.
 The increase in the use of computers has spurred the
advancement in many computer related areas
including CAD, CAM and CNC machine tools.
 RP systems could not have been possible without the
existence of CAD.
HISTORICAL DEVELOPMENT
 The development of RP is closely tied in with the
development of applications of computers in the industry.
 The increase in the use of computers has spurred the
advancement in many computer-related areas including
CAD, CAM and CNC machine tools.
 RP systems could not have been possible without the
existence of CAD.
 Advancements in fields such as manufacturing systems
and materials are been important in the development of
RP systems.
Table: Historical
Development of RP and
related
Year of technologies
inception Technology
 1770 Mechanization
 1946 First Computer
 1952 First numerical control(NC) machine tool
 1960 First Commercial laser
 1961 First commercial robot
 1963 First interactive graphics system(early
version of CAD)
 1988 First commercial RP System
Three Phases of Development
Leading to RP
 Prototyping or model making in the traditional sense is an
age-old practice.
 The intention of having a physical prototype is to realize the
conceptualization of a design.
 A prototype is usually required before the start of the full
production of the product.
 The fabrication of prototypes is experimented in many
forms- material removal, castings, molds, joining with
adhesives etc. and with many material types aluminum, zinc,
wood etc.
Cont…
 Prototyping processes have gone through three phases

of development:

 First Phase : Manual Prototyping

 Second Phase : Soft or Virtual Prototyping

 Third Phase : RP
First Phase : Manual Prototyping
 Prototyping has begun as early as humans started to develop
tools to help them live.
 Prototyping as applied to products , prototype development
began several centuries ago.
 Prototypes typically are not very sophisticated and fabrication of
prototypes takes on average about four weeks, depending on the
level of complexity and representativeness.
 The techniques used in making these prototypes tend to be craft-
based and are usually extremely labor intensive.
Second Phase : Soft or Virtual
Prototyping
 As applications of CAD/CAE/CAM become more widespread,
the early 1980s saw the evolution of the second phase.
 Virtual prototyping takes on a new meaning as more computer
tools become available-computer models can now be stressed,
tested, analyzed and modified as if they were physical
prototypes.
 Prototypes become twice as complex as before.
 Material limitations
Third Phase : RP
 RP of physical parts, otherwise known as solid free form
fabrication or desktop manufacturing or layer manufacturing
technology.
 On an average of 3 weeks
 More complex parts are being manufactured.
 Time saving
FUNDAMENTALS OF RP
1. A model or component is modeled on a computer – aided
design-CAD-CAM system.
Physical part to be built must be in closed surfaces defined
an enclosed volume.
Means the data must specify the inside, the outside and the
boundary of the model.
Solid modeling.

This requirement ensures that all horizontal cross-sections


that are essential to RP are closed curves to greate the solid
object.
Cont…
2. The solid or surface model to be built is next converted into a format
dubbed the “STL”(Stereolithography) file format which originates from
3D systems.
The STL file format approximates the surfaces of the model by
polygons.
Highly curved surfaces must employ many polygons, which
mean that STL files for curved parts can be very large.
There are some RP systems which also accept data in the initial
graphics exchange specifications(IGES) format.
Cont…
3. An computer program analyzes an .STL file that defines the model to be
fabricated and “slices” the model into cross-sections.
The cross-sections are systematically recreated through the
solidification of either liquids or powders and then combined to
form a 3D model.
Another possibility is that the cross-sections are already thin,
solid laminations and these thin laminations are glued together
with adhesives to a 3D model.
Other similar methods may also be employed to build the
model.
RP wheel depicting the
four major aspects of RP
INPUT

METHOD

MATERIAL

APPLICATIONS
Advantages of RP
Direct Benefits:
Benefits to Product Designers
Benefits to the tooling and
Manufacturing Engineer
• Indirect Benefits:
Benefits to marketing
Benefits to the Consumer
Classification of RP
Systems
RP Systems can be categorized
 Liquid Based: These RP systems have initial
form of material in liquid state. Through a
process commonly known as curing, the liquid
is converted to the solid state.
 Solid Based: These RP systems are meant to
encompall all forms of material in the solid
state.The solid form can include the shape in
the form of wires, rolls, laminations and
pellets.
 Powder Based: It is intentionally created as a
category outside the solid-based RP systems
to mean powder in grain-like form.
Liquid Based
3D systems Stereolithograghy
Apparatus(SLA)
Object Geometrics LTd’s Polyjet
Cubital’s Solid Ground Curing (SGC)
D-MEC’s Solid Creation System(SCS)
CMET’s Solid Object Ultraviolet-Laser
Printer (SOUP)
SOLID BASED
Stratasy’s Fused Deposition Modeling (FDM)

Cubic Technologies Laminated Object (LOM)

Solidscapes benchtop system

Shape Deposition Manufacturing Process

Kira’s Paper Lamination Tech(PLT)


POWDER BASED
 3D System’s Selective Laser Sintering(SLS)

 Optomec’s Laser Engineered Net Shaping (LENS)

 Arcam’s Electron Beam Melting (EBM)

Z Corporations Three-Dimensional Printing (3DP)

 3D-Micromac AG’s Microsintering


RP PROCESS CHAIN
INTRODUCTION:

There are three fundamental


fabrication processes, they are subtractive,
additive and formative fabricators.
 Subtractive process: material are removed(CNC)
 Additive process:Material added (RP)
 Formative fabrication process: plastic injection
molding
Three types of
fundamental fabrication
processes
RP PROCESS CHAIN
1) 3D Modeling
2) Data Conversion and
Transmission
3) Checking and Preparing
4) Building
5) Post Processing
RP PROCESS CHAIN:
Distinction Between AM
and CNC Machining:
1) Material
2) Speed
3) Complexity
4) Accuracy
5) Geometry
6) Programming
Industries Currently Using AM:

1) Vehicle
2) Medical
3) Consumer Goods
4) Manufacturing
5) Electronics
Need of AM:
1) Customize Models
2) Lower Costs
3) Shorter Lead Time
4) Freedom to Design
5) Can be Modified Easily
6) Complex geometry

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