Development of Novel Hybrid Manufacturing Technique for Manufacturing Support Structures Free Complex Parts

2019 ◽  
Author(s):  
Haris Ali Khan ◽  
Toyosi Ademujimi
Keyword(s):  
Additive Manufacturing ◽  
Support Structures ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Novel Approach ◽  
Subtractive Manufacturing ◽  
Need For Support ◽  
Near Net Shape ◽  
Manufacturing Techniques ◽  
Complex Parts

Abstract This study unearths a novel approach utilizing conventional subtractive manufacturing technology (5-axis CNC milling center) to realize additively manufactured complex geometries without employing support structures. The proposed approach was based on benefiting from the precision and accuracy of subtractive manufacturing while leveraging the freedom of design of additive manufacturing (AM) process. The desired objectives were achieved in a three-stepped methodology where initially the CNC machine was modified to adapt the 3D printing protocols while in the second step, additional hardware was retrofitted on the conventional CNC machine making it compatible to print 3D parts. A “geometric subsection” approach was adopted as the third step where the desired printed part was divided in different subsections based on the overhang angles and the rotational axes of the CNC machine was then utilized in a manner to eliminate the need for support structures. The manufactured AM part can then be post-processed employing the same machining platform. The proposed approach thereby also served as a next step in evolution of done-in-one processes by printing near-net shape components through additive manufacturing and then promptly acquiring the net shape through subtractive manufacturing techniques.

scholarly journals An Architecture for Hybrid Manufacturing Combining 3D Printing and CNC Machining

2016 ◽  
Vol 2016 ◽  
pp. 1-12 ◽  
Author(s):  
Marcel Müller ◽  
Elmar Wings
Keyword(s):  
Additive Manufacturing ◽  
Cnc Machining ◽  
Numerical Control ◽  
Manufacturing Processes ◽  
Hybrid Manufacturing ◽  
Cnc Machine ◽  
Subtractive Manufacturing ◽  
3D Printed ◽  
One Machine ◽  
Complex Parts

Additive manufacturing is one of the key technologies of the 21st century. Additive manufacturing processes are often combined with subtractive manufacturing processes to create hybrid manufacturing because it is useful for manufacturing complex parts, for example, 3D printed sensor systems. Currently, several CNC machines are required for hybrid manufacturing: one machine is required for additive manufacturing and one is required for subtractive manufacturing. Disadvantages of conventional hybrid manufacturing methods are presented. Hybrid manufacturing with one CNC machine offers many advantages. It enables manufacturing of parts with higher accuracy, less production time, and lower costs. Using the example of fused layer modeling (FLM), we present a general approach for the integration of additive manufacturing processes into a numerical control for machine tools. The resulting CNC architecture is presented and its functionality is demonstrated. Its application is beyond the scope of this paper.

Computational Study of Reinforcement Mechanisms of Cuttlefish Bone Inspired Structure for 3D Printing

2021 ◽  
Author(s):  
Brandon Bethers ◽  
Yang Yang
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Computational Study ◽  
High Energy ◽  
Simulation Software ◽  
Support Structures ◽  
Common Support ◽  
Potential Applications ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Abstract Cuttlebone, the internal shell structure of a cuttlefish, presents a unique labyrinthian wall-septa design that promotes high energy absorption, porosity, and damage tolerance. This structure offers us an inspiration for the design of lightweight and strong structures for potential applications in mechanical, aerospace and biomedical engineering. However, the complexity of the cuttlebones structural design makes its fabrication by traditional manufacturing techniques not feasible. The advances in additive manufacturing (3D printing) make highly complex structures like cuttlebone possible to manufacture. In this work, the authors sought to establish comparative data between cuttlebone structures and some common support structures used in additive manufacturing. The structures compared to cuttlebone in this work include the cubic, honeycomb and triangular support structures. This was accomplished by using CAD modeling and simulation software. This study found that the cuttlefish structures had higher average stress values than the others but similar average strain values. This leads to a higher modulus of elasticity for the cuttlebone structures. The data suggests that further research into cuttlebone structures could produce future designs that improve upon the current well-established additive manufacturing support structures. Further study will be performed for the 3D printing of cuttlebone inspired structures by using various types of materials, such as soft and rigid polymers, functional ceramics, composites, and metals.

The Analyses of Working Parameters for a 3D Complex Part Manufacturing by CNC Machine

2015 ◽  
Vol 808 ◽  
pp. 286-291 ◽  
Author(s):  
Vasile Adrian Ceclan ◽  
Ioan Alexandru Popan ◽  
Sorin Dumitru Grozav ◽  
Cristina Ștefana Miron-Borzan ◽  
Ivan Kuric
Keyword(s):  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Complex Part ◽  
Cad Cam ◽  
Working Parameters ◽  
Complex Parts ◽  
Cam Software ◽  
New Strategies ◽  
Made In

In this paper I want to presents the process for manufacturing one complex parts made by aluminum alloy. For manufacturing this complex part I used CAD/CAM software, CNC milling machine and same special tools. Starting from the 3D model made in SolidWorks was manufactured this complex part, using new strategies for CNC milling. To be made this chain of pieces it is necessary to use smart software for this process.

Simulation of Hyper-Elasticity by Shape Estimation

2021 ◽  
pp. 1-11
Author(s):  
Christopher-Denny Matte ◽  
Tsz Ho Kwok
Keyword(s):  
Additive Manufacturing ◽  
Raw Material ◽  
Shape Estimation ◽  
Linear Deformation ◽  
Shape Factors ◽  
Hyperelastic Materials ◽  
Novel Approach ◽  
Non Linear ◽  
Linear Material ◽  
Manufacturing Techniques

Abstract The simulation of complex geometries and non-linear deformation has been a challenge for standard simulation methods. There has traditionally been a trade-off between performance and accuracy. With the popularity of additive manufacturing and the new design space it enables, the challenges are even more prevalent. Additionally, multiple additive manufacturing techniques now allow hyperelastic materials as raw material for fabrication and multi-material capabilities. This allows designers more freedom but also introduces new challenges for control and simulation of the printed parts. In this paper, a novel approach to implementing non-linear material capabilities is devised with negligible additional computations for geometry-based methods. Material curves are fitted with a polynomial expression, which can determine the tangent modulus, or stiffness, of a material based on strain energy. The moduli of all elements are compared to determine relative shape factors used to establish an element's blended shape. This process is done dynamically to update a material's stiffness in real-time, for any number of materials, regardless of linear or non-linear material curves.

From Conventional to Additive Manufacturing: Determining Component Fabrication Feasibility

2018 ◽  
Author(s):  
Seyedeh Elaheh Ghiasian ◽  
Prakhar Jaiswal ◽  
Rahul Rai ◽  
Kemper Lewis
Keyword(s):  
Additive Manufacturing ◽  
Economic Feasibility ◽  
The Core ◽  
Industrial Grade ◽  
Wide Range ◽  
Subtractive Manufacturing ◽  
Continuous Objects ◽  
Manufacturing Techniques ◽  
Primary Assessment ◽  
Core Functionality

The use of additive manufacturing (AM) for fabricating industrial grade components has increased significantly in recent years. Numerous industrial entities are looking to leverage new AM techniques to enable fabrication of components that were typically manufactured previously using conventional manufacturing techniques such as subtractive manufacturing or casting. Therefore, it is becoming increasingly important to be able to rigorously evaluate the technical and economic feasibility of additively manufacturing a component relative to conventional alternatives. In order to support this evaluation, this paper presents a framework that investigates fabrication feasibility for AM from three perspectives: geometric evaluation, build orientation/support generation, and resources necessary (i.e., cost and time). The core functionality of the framework is enabled on voxelized model representation, discrete and binary formats of 3D continuous objects. AM fabrication feasibility analysis is applied to 34 various parts representing a wide range of manifolds and valves manufactured using conventional manufacturing techniques, components commonly found in the aerospace industry. Results obtained illustrate the capability and generalizability of the framework to analyze intricate geometries and provide a primary assessment for the feasibility of the AM process.

scholarly journals Engineering and Economic Aspects of Additive Manufacturing in Energy Related Industries

2020 ◽  
Author(s):  
Sandip Dutta ◽  
Sagar Dasgupta ◽  
Geetha Chimata
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Production Methods ◽  
Energy Applications ◽  
Recent Developments ◽  
Subtractive Manufacturing ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing ◽  
Am Processes

Additive manufacturing is the buzz word these days and many companies are leaning on this technology to leap forward in un-chartered design space that promises to give better performance at impossible to reach design goals with the current manufacturing methods. This paper addresses recent developments that have occurred in Energy related businesses with the adoption of 3D printing, also known as Additive Manufacturing (AM). It covers what and why of additive manufacturing; what constitutes energy and AM industry; current activities in AM for energy; AM for different energy sectors; AM processes; AM applications; selected patents in additive manufacturing associated with energy applications; and economic and financial aspects of AM in energy related industries. In this review paper it was noted that in-spite of phenomenal growth in AM, it seldom replaces traditional production methods due to associated constraints. Many companies are finding complimentary AM processes along with subtractive manufacturing techniques to meet the market demands. However, AM is particularly advantageous and attractive compared to traditional manufacturing methods for low volume complex geometry parts.

scholarly journals Laser Welding of AISI 316L Stainless Steel Produced by Additive Manufacturing or by Conventional Processes

2021 ◽  
Vol 5 (4) ◽  
pp. 136
Author(s):  
Morgane Mokhtari ◽  
Pierrick Pommier ◽  
Yannick Balcaen ◽  
Joel Alexis
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Laser Welding ◽  
Aisi 316L Stainless Steel ◽  
Powder Bed ◽  
Size Limitation ◽  
Common Technique ◽  
Cold Rolled ◽  
Manufacturing Techniques ◽  
Complex Parts

Among all the additive manufacturing techniques, Laser Powder Bed Fusion (LBPF), also called Selective Laser Melting (SLM), is the most common technique due to its high capability of building complex parts with generally improved mechanical properties. One of the main drawbacks of this technique is the sample size limitation, which depends on elaborating chamber dimensions. In this study, we investigate the viability of obtaining large parts with the laser welding of additive manufactured plates. A comparison of the microstructure and the tensile mechanical properties of SLM-welded plates and cold-rolled welded plates was performed. This paper shows the possibility of obtaining defect-free parts. Even if welding has a low impact on the microstructure of the SLM samples, fractures are located on the fusion zone, and a decrease in ductility of around 30% compared to the base metal is observed.

Recent Advancement in Additive Manufacturing

2019 ◽  
pp. 1-19
Author(s):  
Satyanarayana Kosaraju ◽  
Krishna Mohan B. ◽  
Swadesh Kumar Singh
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Wide Spectrum ◽  
Cutting Tools ◽  
Three Dimensional ◽  
Solid Model ◽  
Industrial Manufacturing ◽  
Step Procedure ◽  
Near Net Shape ◽  
Manufacturing Techniques

Additive manufacturing (AM) is acquiring attention in the field of manufacturing. The technique facilitates building of parts through the addition of materials using a computerized three-dimensional solid model. However, the process does not require any coolants, cutting tools, or other resources that are used in conventional manufacturing. The numerous advantages over conventional manufacturing have created interest towards the applications of additive manufacturing in the field of engineering. The governing fundamental principles of additive manufacturing offer a wide spectrum of advantages which includes design, geometric flexibility, near-net-shape capabilities, and fabrication using various materials, reducing the cycle time for manufacturing and overall savings in both energy and costs. The chapter provides a step-by-step procedure for generation of a component through 3D printing and a brief discussion on advanced AM techniques. These can produce high-quality products at high speed and can be used as industrial manufacturing techniques.

scholarly journals An Additive Manufacturing Method Using Large-Scale Wood Inspired by Laminated Object Manufacturing and Plywood Technology

Polymers ◽  
2020 ◽  
Vol 13 (1) ◽  
pp. 144
Author(s):  
Yubo Tao ◽  
Qing Yin ◽  
Peng Li
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Complex Geometries ◽  
Layer Height ◽  
Manufacturing Method ◽  
Laminated Object Manufacturing ◽  
Subtractive Manufacturing ◽  
Manufacturing Techniques ◽  
Further Development ◽  
Thickness Layer

Wood-based materials in current additive manufacturing (AM) feedstocks are primarily restricted to the micron scale. Utilizing large-scale wood in existing AM techniques remains a challenge. This paper proposes an AM method—laser-cut veneer lamination (LcVL)—for wood-based product fabrication. Inspired by laminated object manufacturing (LOM) and plywood technology, LcVL bonds wood veneers in a layer-upon-layer manner. As demonstrated by printed samples, LcVL was able to retain the advantageous qualities of AM, specifically, the ability to manufacture products with complex geometries which would otherwise be impossible using subtractive manufacturing techniques. Furthermore, LcVL-product structures designed through adjusting internal voids and wood-texture directionality could serve as material templates or matrices for functional wood-based materials. Numerical analyses established relations between the processing resolution of LcVL and proportional veneer thickness (layer height). LcVL could serve as a basis for the further development of large-scale wood usage in AM.

scholarly journals Individual layer fabrication (ILF): a novel approach to additive manufacturing by the use of wood

2021 ◽  
Author(s):  
Klaudius Henke ◽  
Daniel Talke ◽  
Frauke Bunzel ◽  
Birger Buschmann ◽  
Carsten Asshoff
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Thin Layer ◽  
Mechanical Pressure ◽  
Individual Layer ◽  
Selective Binding ◽  
Laminated Object Manufacturing ◽  
Novel Approach ◽  
Manufacturing Techniques ◽  
The Individual

AbstractA novel process named ‘individual layer fabrication (ILF)’ is presented, in which objects are built up by laminating individually contoured wood-based panels. However, contrary to the well-known process of ‘laminated object manufacturing (LOM)’, in ILF, the individual panels are not shaped by a subtractive process but additively by selective binding of wooden particles. The particles are spread as a thin layer onto a built platform. A liquid adhesive is then applied only to those areas where the contoured panel is to be generated. As each layer is fabricated individually, the ILF process allows the application of mechanical pressure. Thereby, compared to other additive manufacturing techniques, the necessary amount of binder can be significantly reduced and mechanical properties comparable to particle boards can be achieved.

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