scholarly journals Design And Validation of A Sheet Metal Clamping System For Additive Manufacturing and Post-Processing

2021 ◽  
Author(s):  
Julian Ferchow ◽  
Marvin Bühler ◽  
Marcel Schlüssel ◽  
Livia Zumofen ◽  
Christoph Klahn ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Sheet Metal ◽  
Process Chain ◽  
Post Processing ◽  
Powder Bed ◽  
Fundamental Investigation ◽  
Clamping System ◽  
Universal Interface ◽  
Sheet Metal Profiles ◽  
Milling Tools

Abstract Automated clamping for post-processing of mass-customized parts is a challenging step in the laser powder bed fusion (LPBF) process chain. In this study, a novel modular sheet metal clamping system was developed that uses disposable sheet metal profiles as a universal interface for the LPBF, robotic handling, and milling processes. Based on a fundamental investigation of hybrid additive manufacturing, the sheet metal clamping system was designed to use the same interface for the LPBF and milling processes. Subsequent an end-to-end validation was performed for the entire process chain. The concept of the sheet metal clamping system gives milling tools access to a part on five to six sides. Further, the part can be accessed from the top and bottom sides, and simplifying the removal of LPBF supports. No clamping forces are induced in the LPBF part, which is especially important for filigree structures. The sheet metal clamping system’s underlying concept could be adapted to automating the LPBF process chain for applications such as prosthetic dentistry.

Hybride Fertigung mittels Laser-Strahlschmelzen/Hybrid manufacturing by laser-based powder bed fusion

2021 ◽  
Vol 111 (06) ◽  
pp. 363-367
Author(s):  
Lukas Langer ◽  
Matthias Schmitt ◽  
Georg Schlick ◽  
Johannes Schilp
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Hybrid Manufacturing ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Manufacturing Costs ◽  
Additive Fertigung ◽  
Powder Bed

Die additive Fertigung ermöglicht komplexe Geometrien und individualisierte Bauteile. Die hohen Material- und Fertigungskosten können ein Hindernis für einen wirtschaftlichen Einsatz sein. In der hybriden additiven Fertigung werden die Vorteile konventioneller sowie additiver Fertigungsverfahren kombiniert. Für eine weitere Steigerung der Wirtschaftlichkeit und Effizienz werden nichtwertschöpfende Schritte der Prozesskette identifiziert und Automatisierungsansätze entwickelt.   Additive manufacturing enables complex geometries and individualized components. However, high material and manufacturing costs can be a hindrance for economical use. Hybrid additive manufacturing combines the advantages of conventional with additive manufacturing processes. For a further increase in profitability and efficiency, non-value-adding steps in the process chain are identified and automation approaches developed.

Additive manufacturing a powerful tool for the aerospace industry

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mahyar Khorasani ◽  
AmirHossein Ghasemi ◽  
Bernard Rolfe ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Production Costs ◽  
Process Chain ◽  
Post Processing ◽  
Jet Engine ◽  
Content Type ◽  
Support Optimization ◽  
The Cost

Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization. Design/methodology/approach Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy. Findings Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology. Originality/value Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.

Nachbearbeitung additiv gefertigter Fräswerkzeuge/Exploiting the full potential by developing seamless process chains

2021 ◽  
Vol 111 (11-12) ◽  
pp. 818-823
Author(s):  
Tobias Kelliger ◽  
Christoph Zachert ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Additive Manufacturing ◽  
Cutting Tools ◽  
Design Guidelines ◽  
Full Potential ◽  
Process Chain ◽  
Post Processing ◽  
Additive Fertigung ◽  
Process Chains ◽  
Individual Design ◽  
Design And Production

Durch additive Fertigung können Zerspanwerkzeuge beanspruchungsgerecht und individuell designt und gefertigt werden. Um das volle ökonomische und ökologische Potenzial dieser Werkzeuge auszuschöpfen, ist eine übergreifende Prozesskettenbetrachtung von der Konstruktion über die Fertigung bis zur spanenden Nachbearbeitung nötig. Dabei müssen übergreifende Lösungen und Gestaltungsrichtlinien entwickelt werden.   Additive manufacturing enables an individual design and production of cutting tools that fulfills the requirements. However, the full economic and ecological potential can only be exploited by considering the entire process chain from design and production to post-processing. General solutions and design guidelines have to be developed.

Additive Manufacturing and Post Processing of Alloy 22 by Laser Powder Bed Fusion

2021 ◽  
pp. 102490
Author(s):  
Dongqing Yan ◽  
Milad Ghayoor ◽  
Kai Coldsnow ◽  
Hadi Pirgazi ◽  
Behrang Poorganji ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Post Processing ◽  
Powder Bed ◽  
Alloy 22

scholarly journals Numerical Investigation into the Effect of Different Parameters on the Geometrical Precision in the Laser-Based Powder Bed Fusion Process Chain

2020 ◽  
Vol 10 (10) ◽  
pp. 3414
Author(s):  
David De Baere ◽  
Mandanà Moshiri ◽  
Sankhya Mohanty ◽  
Guido Tosello ◽  
Jesper Henri Hattel
Keyword(s):  
Heat Treatment ◽  
Stress Relaxation ◽  
Heat Treatment Temperature ◽  
Base Plate ◽  
Treatment Temperature ◽  
Chain Model ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Post Processing ◽  
Powder Bed

Due to the layer-by-layer nature of the process, parts produced by laser-based powder bed fusion (LPBF) have high residual stresses, causing excessive deformations. To avoid this, parts are often post-processed by subjecting them to specially designed heat treatment cycles before or after their removal from the base plate. In order to investigate the effects of the choice of post-processing steps, in this work the entire LPBF process chain is modelled in a commercial software package. The developed model illustrates the possibilities of implementing and tailoring the process chain model for metal additive manufacturing using a general purpose finite element (FE) solver. The provided simplified computational example presents an idealised model to analyse the validity of implementing the LPBF process chain in FE software. The model is used to evaluate the effect of the order of the process chain, the heat treatment temperature and the duration of the heat treatment. The results show that the model is capable of qualitatively capturing the effect of the stress relaxation that occurs during a heat treatment at elevated temperature. Due to its implementation, the model is relatively insensitive to duration and heat treatment temperature, at least as long as it is above the relaxation temperature. Furthermore, the simulations suggest that, when post-processing, it is necessary to perform the stress relaxation before the part is removed from the base plate, in order to avoid a significant increase of the deformation. The paper demonstrates the capability of the simulation tool to evaluate the effects of variations in the process chain steps and highlights its potential usage in directing decision-making for LPBF process chain design.

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