Modelling of Cusp Geometry in Additive Manufacturing Parts Using a Piece-Wise Polynomial

2015 ◽  
Author(s):  
Farzaneh Kaji ◽  
Ahmad Barari
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
High Surface ◽  
3D Models ◽  
Critical Issue ◽  
Layer By Layer ◽  
Layer Manufacturing ◽  
Surface Angle ◽  
Good Agreement

The final dimensional and geometric inaccuracies, and the resulting high surface roughness of the products have been the major problems in employing Additive Manufacturing (AM) technologies. Most of commonly used Additive manufacturing (AM) technologies are developed based on a layer-based manufacturing process to fabricate 3D models. The main critical issue in AM which reduces the surface integrity of the final products is the stair case error which happens due to layer by layer manufacturing process. A new method is presented to model the surface roughness of FDM parts based on considering a new geometry for the cusps. Variety of observations were conducted to model the exact geometry of the cusp. Considering that cusp geometry affects the surface roughness directly, the new geometry was used to predict the surface roughness distribution as a function of layer thickness and surface angle of the final FDM products. The model was validated by designing a set of experiments using 3D measurements of the surface roughness under high resolution surface topography device and the predicted model was in a good agreement with the experimental results.

scholarly journals The Influence of Different Slicer Software on 3d Printing Products Accuracy and Surface Roughness

2021 ◽  
Vol 12 (2) ◽  
pp. 371-380
Author(s):  
Sally Cahyati ◽  
◽  
Haris Risqy Aziz
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
High Surface ◽  
3D Printer ◽  
Layer By Layer ◽  
Additive Manufacturing Technology ◽  
Printing Machine

Rapid Prototyping (RP) is a manufacturing process that produces a 3D model CAD to be a real product rapidly by using additive manufacturing technology. In this case, the product will print layer by layer uses a 3D printer machine. The 3D printer requires slicer software to convert CAD data into data that a 3D printer machine can read. Research is done to analyze the effect of three kinds of slicer software on 3D printing objects on the accuracy and surface roughness of the product. The 3D model CAD is sliced using three different slicer software, namely Ideamaker, Repetier Host, and Cura. The slice model result from each slicer will be printed on a 3D printer machine with the same process parameters to be compared. Then the product's dimensional and surface roughness will be measured to determine the effect of each slicer on product quality. The best quality of the product reflected the most suitable slicer software for the 3D printing machine that used. The best results achieved by Cura slicer because it has resulted in small dimensional deviations (max 0,0308±0,0079) and stabile high surface roughness of the product (max 1,585+059).

scholarly journals Embedded Obfuscated Barcodes for Identification of Genuine Additive Manufactured Parts

2021 ◽  
Author(s):  
Fei Chen ◽  
DINESH PINISETTY ◽  
Nikhil Gupta
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
Intellectual Property ◽  
Manufacturing Process ◽  
New Technologies ◽  
Three Dimensional ◽  
Code Design ◽  
Layer By Layer ◽  
Micro Ct ◽  
Layer Manufacturing

Abstract Additive manufacturing (AM) has been adopted for manufacturing complex shaped highly customized components for aerospace, automotive, and medical fields, where intellectual property protection and counterfeit detection are major concerns. New technologies such as Blockchain have been promising in supply chain authentication. However, AM due to layer-by-layer manufacturing process provides opportunities of embedding information inside the part during manufacturing, which has been explored recently to embed identification codes inside the parts. The present work studies the possibility of printing a barcode inside the additively manufactured part and develops a scheme to obfuscate the code design to read differently from different directions to enhance the security and protect the intellectual property. The embedded three-dimensional codes are scanned using a micro-CT scan. This scheme of embedded obfuscated codes proves to be a highly customizable and efficient process while securing product design files.

scholarly journals Blade Segment with a 3D Lattice of Diamond Grits Fabricated via an Additive Manufacturing Process

2020 ◽  
Vol 33 (1) ◽  
Author(s):  
Bin Chen ◽  
Peng Chen ◽  
Yongjun Huang ◽  
Xiangxi Xu ◽  
Yibo Liu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Service Life ◽  
Manufacturing Process ◽  
Cutting Speed ◽  
Inspection System ◽  
Layer By Layer ◽  
Filling Rate ◽  
Pressure System ◽  
Manufacturing Equipment ◽  
Diamond Blade

Abstract Diamond tools with orderly arrangements of diamond grits have drawn considerable attention in the machining field owing to their outstanding advantages of high sharpness and long service life. This diamond super tool, as well as the manufacturing equipment, has been unavailable to Chinese enterprises for a long time due to patents. In this paper, a diamond blade segment with a 3D lattice of diamond grits was additively manufactured using a new type of cold pressing equipment (AME100). The equipment, designed with a rotary working platform and 16 molding stations, can be used to additively manufacture segments with diamond grits arranged in an orderly fashion, layer by layer; under this additive manufacturing process, at least 216000 pcs of diamond green segments with five orderly arranged grit layers can be produced per month. The microstructure of the segment was observed via SEM and the diamond blade fabricated using these segments was compared to other commercial cutting tools. The experimental results showed that the 3D lattice of diamond grits was formed in the green segment. The filling rate of diamond grits in the lattice could be guaranteed to be above 95%; this is much higher than the 90% filling rate of the automatic array system (ARIX). When used to cut stone, the cutting amount of the blade with segments made by AME100 is two times that of ordinary tools, with the same diamond concentration. When used to dry cut reinforced concrete, its cutting speed is 10% faster than that of ARIX. Under wet cutting conditions, its service life is twice that of ARIX. By applying the machine vision online inspection system and a special needle jig with a negative pressure system, this study developed a piece of additive manufacturing equipment for efficiently fabricating blade segments with a 3D lattice of diamond grits.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Design Considerations for Hybridizing Additive Manufacturing and Direct Write Technologies

2014 ◽  
Author(s):  
K. Blake Perez ◽  
Christopher B. Williams
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Manufacturing Process ◽  
Layer By Layer ◽  
Direct Write ◽  
Systematic Design ◽  
Flexible Polymers ◽  
Conductive Materials ◽  
Design Considerations ◽  
Embedded Electronics

The layer-by-layer nature of additive manufacturing (AM) allows for access to the entire build volume of an artifact during manufacture, including its internal structure. Internal voids are accessible during the build process and allow for components to be embedded and sealed with subsequently printed layers. When AM is combined with Direct Write (DW) of conductive materials, the resulting hybrid process enables the direct manufacture of parts with embedded electronics, including interconnects and sensors. However, the hybridization of DW and AM technologies is non-trivial due to (i) identifying DW materials and processes that are compatible with AM infrastructure, throughput and resolution, (ii) temperature processing requirements, and (iii) interactions between the two materials. In this paper, the authors explore DW technologies and materials to identify those that are most compatible with AM. From this exploration, the authors abstract a set of generalized design considerations for the design of a hybrid AM and DW process. These considerations are then employed in a systematic design process in which a DW system for depositing conductive materials during the PolyJet manufacturing process is realized. The resulting system is able to create embedded functional electronic interconnects and sensors in printed parts composed of both stiff and flexible polymers.

scholarly journals Experimental Investigation on Mechanical Properties of Part Fabricated by Wire Arc Additive Manufacturing Process

2021 ◽  
Author(s):  
Vivek Kumar P ◽  
◽  
Soundrapandian E ◽  
Jenin Joseph A ◽  
Kanagarajan E ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Casting Process ◽  
Significant Rise ◽  
Layer By Layer ◽  
Cnc Machine ◽  
Hardness Tester ◽  
Wire Arc Additive Manufacturing

Additive manufacturing process is a method of layer by layer joining of materials to create components from three-dimensional (3D) model data. After their introduction in the automotive sector a decade ago, it has seen a significant rise in research and growth. The Additive manufacturing is classified into different types based upon the energy source use in the fabrication process. In our project, we used self-build CNC machine that runs MACH3 software, as well as the MACH3 controller is used to control the welding torch motion for material addition through three axis movement (X, Y and Z). In the project we used ER70 S-6 weld wire for the fabrication and examined its microstructure and mechanical properties. Different layers of the specimen had different microstructures, according to microstructural studies of the product. Rockwell hardness tester used for testing hardness of the product. According to the observation of the part fabricated components using the Wire Arc Additive Manufacturing process outperformed the mechanical properties of mild steel casting process. The product fabricated by Wire Arc Additive Manufacturing process properties is superior to conventional casting process.

scholarly journals Additive manufacturing process creates local surface roughness modifications leading to variation in cell adhesion on multifaceted TiAl6V4 samples

Bioprinting ◽  
2019 ◽  
Vol 16 ◽  
pp. e00054 ◽  
Author(s):  
Augustin Lerebours ◽  
Pascale Vigneron ◽  
Salima Bouvier ◽  
Alain Rassineux ◽  
Maxence Bigerelle ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cell Adhesion ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Local Surface

scholarly journals Theoretical and Experimental Investigation on the 3D Surface Roughness of Material Extrusion Additive Manufacturing Products

Polymers ◽  
2022 ◽  
Vol 14 (2) ◽  
pp. 293
Author(s):  
Shijie Jiang ◽  
Ke Hu ◽  
Yang Zhan ◽  
Chunyu Zhao ◽  
Xiaopeng Li
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Defects ◽  
Raw Materials ◽  
Fiber Direction ◽  
Layer By Layer ◽  
Forming Process ◽  
Material Extrusion ◽  
Proposed Model ◽  
Wide Range

Material extrusion (ME), one of the most widely used additive manufacturing technique, has the advantages of freedom of design, wide range of raw materials, strong ability to manufacture complex products, etc. However, ME products have obvious surface defects due to the layer-by-layer manufacturing characteristics. To reveal the generation mechanism, the three-dimensional surface roughness (3DSR) of ME products was investigated theoretically and experimentally. Based on the forming process of bonding neck, the 3DSR theoretical model in two different directions (vertical and parallel to the fiber direction) was established respectively. The preparation of ME samples was then completed and a series of experimental tests were performed to determine their surface roughness with the laser microscope. Through the comparison between theoretical and experimental results, the proposed model was validated. In addition, sensitivity analysis is implemented onto the proposed model, investigating how layer thickness, extrusion temperature, and extrusion width influence the samples’ surface roughness. This study provides theoretical basis and technical insight into improving the surface quality of ME products.

Taguchi Design of Experiment for the Optimization of Electrochemical Polishing of Metal Additive Manufacturing Components

2016 ◽  
Author(s):  
Denikka Brent ◽  
Tyler Alyssa Saunders ◽  
Francisco Garcia Moreno ◽  
Pawan Tyagi
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Design Of Experiment ◽  
High Surface ◽  
Stress Concentrations ◽  
Premature Failure ◽  
High Surface Roughness ◽  
Multivariable Process ◽  
Experimental Process ◽  
Suitable Combination

3D Printing (Additive Manufacturing, AM) offers benefits such as lower costs, easier customization and creating complex functional products. However, utilization of AM components in the engineering applications may be severely limited by the high surface roughness. For most industrial uses the high surface roughness can cause stress concentrations, premature failure, and corrosion susceptibility. Unfortunately, conventional surface reduction processes like machining, extrude honing, and sandblasting, may not be feasible for the complex AM components. This research focused on exploring electropolishing as a viable surface smoothing approach for the AM components. However, electropolishing is a multivariable process and requires extensive parameter optimization. We have employed Taguchi’s design of experiment to find the suitable combination of electropolishing parameters. Our Taguchi analysis yielded a set of optimum experimental parameters for the electropolishing of steel AM components. This experimental process reduced the roughness of AM component surfaces as much as ∼63%.

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