scholarly journals Studies on the Process Parameters of Rapid Prototyping Technique (Stereolithography) for the Betterment of Part Quality

2014 ◽  
Vol 2014 ◽  
pp. 1-11 ◽  
Author(s):  
Raju Bangalore Singe Gowda ◽  
Chandra Sekhar Udayagiri ◽  
Drakshayani Doulat Narendra
Keyword(s):  
Rapid Prototyping ◽  
Layer Thickness ◽  
Process Parameters ◽  
Process Model ◽  
Empirical Relation ◽  
Dimensional Accuracy ◽  
Part Quality ◽  
Mechanical Part ◽  
Minimum Number ◽  
Physical Part

Rapid prototyping (RP) has evolved as frontier technology in the recent times, which allows direct transformation of CAD files into functional prototypes where it tremendously reduces the lead time to produce physical prototypes necessary for design verification, fit, and functional analysis by generating the prototypes directly from the CAD data. Part quality in the rapid prototyping process is a function of build parameters such as hatch cure depth, layer thickness, orientation, and hatch spacing. Thus an attempt was made to identify, study, and optimize the process parameters governing the system which are related to part characteristics using Taguchi experimental design techniques quality. The part characteristics can be divided into physical part and mechanical part characteristics. The physical characteristics are surface finish, dimensional accuracy, distortion, layer thickness, hatch cure, and hatch file, whereas mechanical characteristics are flexural strength, ultimate tensile strength, and impact strength. Thus, this paper proposes to characterize the influence of the physical build parameters over the part quality. An L9 orthogonal array was designed with the minimum number of experimental runs with desired parameter settings and also by analysis tools such as ANOVA (analysis of variance). Establishment of experimentally verified correlations between the physical part characteristics and mechanical part characteristics to obtain an optimal process parameter level for betterment of part quality is obtained. The process model obtained by the empirical relation can be used to determine the strength of the prototype for the given set of parameters that shows the dependency of strength, which are essential for designers and RP machine users.

Study on the Process Parameters of MPAW-Based Rapid Prototyping

2007 ◽  
Vol 353-358 ◽  
pp. 1931-1934
Author(s):  
Wurikaixi Aiyiti ◽  
Wan Hua Zhao ◽  
Yi Ping Tang ◽  
Bing Heng Lu
Keyword(s):  
Rapid Prototyping ◽  
Process Parameters ◽  
Gas Flow ◽  
Scanning Speed ◽  
Part Quality ◽  
R Ratio ◽  
Feeding Speed ◽  
Wire Feeding ◽  
The Impact

A direct metal RP (rapid prototyping) process based on micro-plasma arc welding (MPAW) is presented. The impact of R (ratio of width to height of the deposited track’s cross-section) on part quality is investigated. Taguchi method is adopted to analyze the effect of each process parameter on R, and the optimized process parameters are obtained. The results show that the quality of the parts with larger R is better than that with smaller R, and the peak current, duty cycle of pulse duration, wire-feeding speed, scanning speed and plasma gas flow rate all exert significant effects on R. The overlapped surface smoothness, tensile strength and elongation of the parts fabricated with optimized parameters are measured to show obviously better performances than those of the parts fabricated with ordinary process parameters.

scholarly journals Establishment of Process Model for Rapid Prototyping Technique (Stereolithography) to Enhance the Part Quality by Taguchi Method

2014 ◽  
Vol 14 ◽  
pp. 380-389 ◽  
Author(s):  
B.S. Raju ◽  
U. Chandra Shekar ◽  
K. Venkateswarlu ◽  
D.N. Drakashayani
Keyword(s):  
Taguchi Method ◽  
Rapid Prototyping ◽  
Process Model ◽  
Part Quality

The Optimization Design Study of Selective Laser Sintering Process Parameters on the Pro-Coated Sand Mold

2011 ◽  
Vol 55-57 ◽  
pp. 853-858
Author(s):  
Rong Cheng ◽  
Xiao Yu Wu ◽  
Jian Ping Zheng
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Laser Power ◽  
Selective Laser Sintering ◽  
Dimensional Accuracy ◽  
Processing Parameters ◽  
Laser Sintering ◽  
Process Variables ◽  
Scan Speed ◽  
Coated Sand

This paper presents experimental investigations on influence of important process parameters viz., laser power, scan speed, layer thickness, hatching space along with their interactions on dimensional accuracy of Selective Laser Sintering (SLS) processed pro-coated sand mold. It is observed that dimensional error is dominant along length and width direction of built mold. Optimum parameters setting to minimize percentage change in length and width of standard test specimen have been found out using Taguchi’s parameter design. Optimum process conditions are obtained by analysis of variance (ANOVA) is used to understand the significance of process variables affecting dimension accuracy. Scan speed and hatching space are found to be most significant process variables influencing the dimension accuracy in length and width. And laser power and layer thickness are less influence on the dimension accuracy. The optimum processing parameters are attained in this paper: laser power 11 W; scan speed 1200 mm/s; layer thickness 0.5 mm and hatching space 0.25 mm. It has been shown that, on average, the dimensional accuracy under this processing parameters combination could be improved by approximately up to 25% compared to other processing parameters combinations.

An investigation on energy consumption and part quality of stereolithography apparatus manufactured parts

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jizhuang Hui ◽  
Zhiqiang Yan ◽  
Jingxiang Lv ◽  
Yongsheng Liu ◽  
Kai Ding ◽  
...  
Keyword(s):  
Tensile Strength ◽  
Energy Consumption ◽  
Layer Thickness ◽  
Laser Power ◽  
Dimensional Accuracy ◽  
Electrical Energy ◽  
Design Stage ◽  
Content Type ◽  
Part Quality

Purpose This paper aims to investigate the influences of process parameters on part quality, electrical energy consumption. Moreover, the relationship between part quality and energy consumption of UTR9000 photosensitive resin fabricated by stereolithography apparatus (SLA) was also assessed. Design/methodology/approach Main effect plots and contour maps were used to analyze the interactions and effects of various parameters on energy consumption and part quality, respectively. Then, a growth rate was used defined as the percentage of the value of energy consumption (or the part quality) of the sample compared to the minimum value of the energy consumption (or the same part quality), to jointly analyze relationships between part quality and energy consumption on a specific process parameter. Findings The part qualities can be improved with increased energy consumption via adjusting layer thickness, without further increasing energy consumption through adjusting laser power, over-cure and scanning distance. Energy consumption can be highly saved while slightly decreasing the tensile strength by increasing layer thickness from 0.09 mm to 0.12 mm. Energy consumption and surface roughness can be decreased when setting laser power near 290 mW. Setting an appropriate over-cure of about 0.23 mm will improve tensile strength and dimensional accuracy with a little bit more energy consumption. The tensile strength increases nearby 5% at a scanning distance of 0.07 mm compared to that at a scanning distance of 0.1 mm while the energy consumption only increases by 1%. Originality/value In this research, energy consumption and multiple part quality for SLA are jointly analyzed first to accelerate the development of sustainable additive manufacturing. This can be used to assist designers to achieve energy-effective fabrication in the process design stage.

A Benchmark Artifact to Evaluate the Manufacturing of Microfeatures by Digital Light Processing Stereolithography

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Lara Rebaioli ◽  
Irene Fassi
Keyword(s):  
Layer Thickness ◽  
Exposure Time ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Main Process ◽  
Process Performance ◽  
Digital Light Processing ◽  
Specific Process ◽  
Experimental Campaign ◽  
Increasing Demand

Abstract Suitable benchmark artifacts are needed for assessing the technological capabilities and limitations of a specific process or for comparing the performances of different processes. Only a few benchmark artifacts have been specifically designed for features with microscale dimensions, even if their manufacturing is becoming very common due to the increasing demand for miniaturized parts or objects with microscale features. In this study, a suitable benchmark part is designed to evaluate the geometrical performance of a digital light processing (DLP) stereolithography (SLA) system for manufacturing microfeatures. The effect of the main process parameters (i.e., layer thickness and exposure time) and the feature position within the building platform on the process performance was assessed by a specifically studied experimental campaign. The results show that both the analyzed process parameters influence the minimum feasible size of protruding features and that the feature position influences the dimensional accuracy.

Part Build Orientation Optimization and Neural Network-Based Geometry Compensation for Additive Manufacturing Process

2017 ◽  
Vol 140 (3) ◽  
Author(s):  
Sushmit Chowdhury ◽  
Kunal Mhapsekar ◽  
Sam Anand
Keyword(s):  
Neural Network ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Surface Finish ◽  
Quality Measurement ◽  
Dimensional Accuracy ◽  
Build Orientation ◽  
Part Quality ◽  
Heating And Cooling ◽  
Orientation Optimization

Significant advancements in the field of additive manufacturing (AM) have increased the popularity of AM in mainstream industries. The dimensional accuracy and surface finish of parts manufactured using AM depend on the AM process and the accompanying process parameters. Part build orientation is one of the most critical process parameters, since it has a direct impact on the part quality measurement metrics such as cusp error, manufacturability concerns for geometric features such as thin regions and small fusible openings, and support structure parameters. In conjunction with the build orientation, the cyclic heating and cooling of the material involved in the AM processes lead to nonuniform deformations throughout the part. These factors cumulatively affect the design conformity, surface finish, and the postprocessing requirements of the manufactured parts. In this paper, a two-step part build orientation optimization and thermal compensation methodology is presented to minimize the geometric inaccuracies resulting in the part during the AM process. In the first step, a weighted optimization model is used to determine the optimal build orientation for a part with respect to the aforementioned part quality and manufacturability metrics. In the second step, a novel artificial neural network (ANN)-based geometric compensation methodology is used on the part in its optimal orientation to make appropriate geometric modifications to counteract the thermal effects resulting from the AM process. The effectiveness of this compensation is assessed on an example part using a new point cloud to part conformity metric and shows significant improvements in the manufactured part's geometric accuracy.

Optimization of process parameters for dimensional accuracy in an area-forming rapid prototyping system using the Taguchi method

2015 ◽  
Vol 29 (06n07) ◽  
pp. 1540011 ◽  
Author(s):  
Shih-Hsuan Chiu ◽  
Cheng-Chin Chen ◽  
Kun-Ting Chen ◽  
Chun-Hao Su
Keyword(s):  
Taguchi Method ◽  
Rapid Prototyping ◽  
Process Parameters ◽  
Processing Time ◽  
Simple Procedure ◽  
Dimensional Accuracy ◽  
Quality Characteristics ◽  
Optimization Of Process Parameters ◽  
Short Processing Time ◽  
Rapid Prototyping System

Rapid prototyping (RP) technologies have been extensively applied to build products in recent decades. The area-forming rapid prototyping is an emerging RP technology with the advantages of a simple procedure with a short processing time. With the expansion in fields of application, the strictness on product quality has also increased. The dimensional accuracy of a product is one of the most critical quality characteristics. In order to improve the dimensional accuracy of a product from an area-forming RP system, this study optimizes the seven factors via the Taguchi method, and the result is verified with an extra sample.

The Working Principle and Main Technical Factors Influencing on Finished Accuracy of Rapid Prototyping

2011 ◽  
Vol 480-481 ◽  
pp. 1554-1558
Author(s):  
Ji Bao Liu ◽  
Di Wang ◽  
Xiao Jing Li ◽  
Zhi Hua Gao
Keyword(s):  
Rapid Prototyping ◽  
Process Parameters ◽  
Manufacture Technology ◽  
Factors Influencing ◽  
Significant Performance ◽  
Working Principle ◽  
Technical Factors ◽  
Physical Part ◽  
Application Fields ◽  
Digital Manufacture

Rapid prototyping (RP) is a digital manufacture technology based on discrete stacking technology. RP technology can be used to machine complex physical part directly from CAD data without any professional apparatus. The paper also summarized four main RP technologies, discussed the working principle and compared the application fields, machining cost and process parameters in detailed. Finally, the author prospected the significant performance of RP for modern industry, analyzed the merits and faults and indicates the development object for RP technology.

A Rapid Prototyping Apparatus for Forming Ceramic Parts

2007 ◽  
Vol 364-366 ◽  
pp. 383-388 ◽  
Author(s):  
Fwu Hsing Liu ◽  
Yunn Shiuan Liao
Keyword(s):  
Rapid Prototyping ◽  
Process Parameters ◽  
Laser Scanning ◽  
Dimensional Accuracy ◽  
Silica Sol ◽  
Scanning System ◽  
Optimal Process ◽  
Silica Powder ◽  
Ceramic Part ◽  
System A

This article proposes a rapid prototyping apparatus of selective laser sintering for forming silica ceramic green parts. The main differences between the proposed and other RP processes for forming ceramic part are the slurry material used to obtain fine layer thickness and the capability of constructing support structure to increase the dimensional accuracy of the workpiece having an overhang. The RP apparatus developed by us comprises a laser scanning system, a material paving system, and a computer control system. A CO2 laser is adopted to scan over a mixture made of a silica sol and silica powder. The silica sol acts as a binder to gel the silica powder together, which forms a 3D object using laser gelation method. A series of experiments were carried out to obtain the optimal process parameters. An SEM is employed to analyze the microstructure of the ceramic part. It has been found that the smallest layer is of 100 μm thick. The results show that both the accuracy of the material paving mechanism and the optimal process parameters can fulfill the requirements of the RP processes.

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