20131022-Additive Manufacturing & Allied Technologies, Pune

8/13/2019 20131022-Additive Manufacturing & Allied Technologies, Pune

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Additive Manufacturing &

Allied Technologies

K.P. KarunakaranProfessor, Mechanical Engineering

Coordinator, Rapid Manufacturing Laboratory

IIT Bombay


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Principle of AM

Three Considerations in Selection of AM Technology

AM Research in IIT Bombay

Benefits & Applications

Significant Benefits & Applications

Allied Technologies (pre-/in-situ/post-build)

Rapid Manufacturing = AM + Allied Technologies

Three Levels of RM

Conclusions

Outline


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PrincipleHow to make things faster?

The two parts of automation are:

i. Automation of process:(a) Hard automation (automats, SPMs, transfer lines)

(b) Soft automation (CNC machine, robot, AGV, AS&RS, FMS)ii. Automation of process planning (CAPP):

(a) CAPP for subtractive processes: Failure except axi-sym., prismatic and some 3-axis(b) CAPP for additive processes: RP

The goal is to speed up the design, evaluationandmanufacturingcycles.

Human involvement is the bottleneck to speed. Therefore,eliminate or at least minimize it through automation.

When both are automated, we shall refer it as Total Automation


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-+: Till 1987, manufacturing wasdominated by material subtraction- notonly in machiningbut also in the formativeprocesses such as castingand forging.

The sign change in manufacturing with theadvent ofAdditiveManufacturingby 3DSystems led to total automation inconverting art-to-part (design-to-manufacturingor virtual-to-physical). So, it

is faster and hence called RapidPrototyping.

It is as easy and simple as 2D printing. So,many prefer to call it as 3D Printing.

CNC machineAM machine

PrincipleSign Change in Manufacturing: Minus to Plus


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PrincipleAnalogy with printing
http://en.wikipedia.org/wiki/File:Platen_Printing_press.jpg


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PrincipleAnalogy with printing

Totally automated 2D printing

(Lithography)

Totally automated 3Dprinting

(Stereo-lithography)AM revolutionized the way products are designed and manufacturedtoday. It is an effective tool to compress product development timeand hence gives an edge over the competitors.
http://www.google.co.in/url?sa=i&rct=j&q=mojo+++stratasys&source=images&cd=&cad=rja&docid=nMxHHYz0UiEEBM&tbnid=SX8VQl62TVhO0M:&ved=0CAUQjRw&url=http://investors.stratasys.com/releasedetail.cfm?ReleaseID=671436&ei=TOgTUaPmG4yziQfKn4CgBA&bvm=bv.42080656,d.bmk&psig=AFQjCNGjCoq37aNpGEpIWMhk9JjXUBj41g&ust=1360345509950295http://www.google.co.in/url?sa=i&rct=j&q=HP+printer&source=images&cd=&cad=rja&docid=KEBQfSVc722zDM&tbnid=3-4a-3n2hNY5NM:&ved=0CAUQjRw&url=http://bokarosteelcity.olx.in/hp-printer-iid-419686574&ei=tOQTUaT7BO-yiQfU-YCYBw&bvm=bv.42080656,d.bmk&psig=AFQjCNEgoCiyjPtC49luBJA41FKlwWZyUQ&ust=1360344572428523


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PrincipleDefinition

AMis anautomaticprocessof manufacturingobjects (parts,prototypes, tools

and evenassemblies)directly fromtheirCADmodels

without anycutters,tools orfixturesspecifictotheobjectgeometry. V01-Mono - DICO ZPrinter Processing


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Principle

Once upon a time there lived

four cows in the forest.Every day they used tograze together in a particularspot. They were all friends.One day a lion saw the cowsgrazing together.

The lion wanted to eat them.

So he went to attack one ofthem. But all the cows joinedtogether and fought withhim. The lion had to runaway.

A few days passed and the

cows quarreled amongthemselves and startedgrazing separately. The lionkilled and ate them all oneby one.

Divide and Conquer (for lion)Stay Together (for cows);


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PrincipleNeed for support mechanism

Scaffolding for a water tank

V02-Materialises Mommonth SLA
http://www.google.co.in/url?sa=i&rct=j&q=scaffolding&source=images&cd=&cad=rja&docid=7JEOqT0v6ak3vM&tbnid=5uFKYf1XMIRgUM:&ved=0CAUQjRw&url=http://www.design-laorosa.com/2011/04/scaffolding-just-as-amazing-as.html&ei=WAs2Ue7iHO2yiQff-oEY&bvm=bv.43148975,d.dGI&psig=AFQjCNHhCw9DEMBaQ_4inmA0KrgpJCPupQ&ust=1362582515724700


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3DP

FDM

SLS

SLA

Powder-bed tech.; No laser, just a liquid binder, hence cheap, all materials.ZCorp:Starch; FGM (color); SoliGen:Ceramic; FGM; ProMetal:Metal; FGM

Powder-bed tech.; Laser, hence costly but faster and accurate, all materials.3D Systems:Single machine; EoS:3 different machines; Many clones

Liquid-bed tech.; Laser, hence costly but faster and accurate, photopolymer.3D Systems;Many clones; other photo-polmer sys: SGC, Envisiontec, Objet

Extrusion of thermoplastics; No laser, hence cheap but slow and less accurate.Stratasys (www.stratasys.com)

LOMJoining profiled laminates; not sophisticated laser, hence cheap. Fast.Cubic (www.cubic.com)/ SolidDimensions

PrinciplePopular AM processes
http://localhost/var/www/apps/conversion/tmp/scratch_6/3DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avihttp://localhost/var/www/apps/conversion/tmp/scratch_6/Extra%203DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avihttp://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20EoS-Sand%20Mold.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/photonic-laser-sintering.mpeghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20LOM.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20LOM.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20EoS-Sand%20Mold.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/photonic-laser-sintering.mpeghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/3DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avihttp://localhost/var/www/apps/conversion/tmp/scratch_6/Extra%203DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avi


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3DP

FDM

SLS

SLA

V01-Mono - DICO ZPrinter Processing

V03a-EoS-Sand-SLS-in ACTechV03b-EoS-DMLS

V02-Materialises Mommonth SLA

V04-FDM process

LOM V05-LOM

PrinciplePopular AM processes - Videos
http://localhost/var/www/apps/conversion/tmp/scratch_6/3DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avihttp://localhost/var/www/apps/conversion/tmp/scratch_6/Extra%203DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avihttp://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20EoS-Sand%20Mold.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/photonic-laser-sintering.mpeghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20LOM.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20LOM.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/SLA-Mommoth-Materialise.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/1b%20EoS-Sand%20Mold.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/photonic-laser-sintering.mpeghttp://localhost/var/www/apps/conversion/tmp/scratch_6/1a%20FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/Video00-FDM%20process.mpghttp://localhost/var/www/apps/conversion/tmp/scratch_6/3DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avihttp://localhost/var/www/apps/conversion/tmp/scratch_6/Extra%203DP1%20Mono%20-%20DICO%20ZPrinter%20Processing.avi


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The greatness of

this man lies in his

simplicity!Gandhi and

Ganapathy dont

complain!!Coarse resolution Fine resolution

PrincipleGeometric Input to 3DP/RP: STL format


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solid AutoCADfacet normal 0.0000000e+000 0.0000000e+000 1.0000000e+000

outer loop

vertex 1.0000000e+001 0.0000000e+000 1.0000000e+001

vertex 1.0000000e+001 1.0000000e+001 1.0000000e+001

vertex 0.0000000e+000 1.0000000e+001 1.0000000e+001

endloop

endfacet

facet normal 1.0000000e+000 0.0000000e+000 0.0000000e+000

outer loop

vertex 1.0000000e+001 0.0000000e+000 0.0000000e+000vertex 1.0000000e+001 1.0000000e+001 0.0000000e+000

vertex 1.0000000e+001 1.0000000e+001 1.0000000e+001

endloop

endfacet

endsolid AutoCAD

PrincipleGeometric Input to 3DP/RP: STL format


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Consideration in the Selection of RP

1 2 3

Material Min. layer thickness Support mechanism

Quality requirementinfluencing strength,

weight,life,transparency etc.

Quality requirementinfluencing geometry

(accuracy and surfacefinish)

Quality requirementinfluencing surface

finish of undercutregions

Requirementinfluencing

(a) additionalmaterial, (b) time, (c)cost, (d) feasibility ofmanufacture

3

Solid-powder:High material variety; simple support mech.Solid-sheets: High material variety; Fast; ease of handling;material wastageSolid-wire: Ease of feeding; high material variety andutilizationLiquid: Excellent accuracy; transparency; Complex supportmech.Gas: Not yet but why not!


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AM Research in IIT BombayHybrid Layered Manufacturing (HLM)

3-axis HLM

5-axis HLM

Multiple torches

MIG

TIG

Laser


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3-Axis HLM 5-Axis HLM (Positional) 5-Axis HLM (Continuous)

Monolithic dies

Composite Dies with conformal cooling

Components without undercuts

Components with undercuts

Components with several 3-axis features in different

orientations

Impeller

Blisks

AM Research in IIT BombayCapabilities of HLM

Videos:V06a 5-ax depositionV06b 5-ax machining


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CAD Model Near-net Shape Final Shape

Boein

gsTiPart

BuiltU

singLAM

AlImpellerBuilt

UsingHLM

AM Research in IIT BombayComparison of 5-axis MIG-HLM withAerometsLAM


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AM Research in IIT BombayHuge polystyrene prototyping: Seg. Obj. Mfg. (SOM)

V07-SOM


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B fit & A li ti


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Benefits & ApplicationsAM for Common Public (June 2013!)

B fit & A li ti


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Benefits & ApplicationsHigh Bandwidth Communication Tool: Gas Turbine

Rs. 19,80,000

(30,000 Euro )

3 Weeks (Time-bound deliverythrough extensiveoutsourcing)

High bandwidthcommunication

tools

1:1 working model(1.1m long)

V08-GTRE Engine

B fit & A li ti


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Benefits & ApplicationsMany design iterations within limited time

Design iterations improve quality of

design. But they also consume resources.

Never evaluate an idea at the time ofbrainstorming.

Never fall in love with your own ideas; thiswill block newer ideas



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Benefits & ApplicationsVarious applications

Concept models for bettervisualization (high bandwidthcommunication tool)

Models to check the aesthetic appeal;also for market survey.

Models for form, fit and functionaltests

Models for stress analysis usingphoto-elasticity

Models for wind tunnel tests Models for design review

Assemblies can be made withoutjoints. It can make parts impossible byother manufacturing methods.

RP models can be sent along with theinquiries; RP models can be submittedalong with the quotations.

Medical applications in conjunctionwith VR, AR & RE.

RP also has its applications inmicro/nano-applications.

RP is emerging into RapidManufacturing.

Essentially RP cuts down product

development time and RT cuts downproductionizing time. With anintegrated approach, RP, RT & RMcan shorten time to market.



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Benefits & ApplicationsPhoto-elasticity models, working prototypes, patterns

Fully functional prototypes

Transparent models for photo-elasticitystudiesConcept model

Material translationthrough Investment Casting



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Benefits & ApplicationsMedical (models, prosthetics & implants); micro-RP

Medical applications:Reverse Engineering, Virtual Reality, AugmentedReality, RP and RT have far reaching implications in medicine!

MEMS[MicroTek, Germany]

0.9 OD; 0.4 ID; 0.05m

Significant Benefits & Applications


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Significant Benefits & ApplicationsFeatures difficult/impossible by other means

1. Conformal cooling channels

3. Gradient Materials

5. Difficult or Impossible Shapes

Design used to be constrained by the manufacturing limitations in thepast. Additive Manufacturing has made the following possible givingdesigners greater freedom:

So, design innovation need not be limited by the manufacturing

constraints. It should exploit these newer capabilities.

2. Assemblies without joints

4. Non-equilibrium Objects

6. Customized solutions



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Benefits & Applications1. Conformal cooling channels

Cycle time reductionLess distortionGood integrity



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Benefits & Applications2. Assemblies without joints

Thin walled turbine combustionchamber, produced on EOSINT M 270,material EOS Nickel Alloy IN 718.

Courtesy: Materialise Solutions, U.K.

Courtesy: EoS, Germany

Courtesy: Stratasys, USA



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Benefits & Applications3. Gradient Materials; 4. Non-equilibrium Materials

Courtesy: Optomec, USACourtesy: ZCorp, USA



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Benefits & Applications5. Difficult or complex shapes



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Benefits & Applications6. Customized solutions

Allied Technologies (Pre/In-situ/Post-Build)
http://www.google.co.in/url?sa=i&rct=j&q=tooth+cap&source=images&cd=&cad=rja&docid=URxjWFKvAFZhvM&tbnid=Mh0PdyyA5oX2bM:&ved=0CAUQjRw&url=http://www.smiletexas.com/2012/07/dental-mysteries-volume-4-dental-crowns&ei=4FwUUf-5H4-jiQef6ICYDg&bvm=bv.42080656,d.bmk&psig=AFQjCNGcXVCf1L8rfBqXnF1xStZYQPy4bg&ust=1360375355495909


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CAD model

AM part

(i) Poor surface finishdue to stair-step error (ii) Irregularities created duringsupport removal

When surface finish is very poor,tolerance cannot be better than that!

Allied Technologies (Pre/In situ/Post Build)Challenges in AM: Poor external quality



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- Each RP process has alimited materialcomposition, that too, innarrow band of properties

FDMPolymers(thermoplastics)SLA Photo-polymerSLS/3DPGood variety from

polymer to metal but one

machine for each.LOMPaper

- Inherently anisotropic

- All RP materials areproprietary- Due to open loop (absenceof human)

- Commercial reasons:

Exorbitantly priced (40-60%of cost is material)

Allied Technologies (Pre/In situ/Post Build)Challenges in AM: Poor internal quality



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Matl: Ti64; Size: 83 x 68 x 131; layer thk. = 0.040 (1700); Time: 60 hrs.

MCP Realizerat LERMPS-

UTBM, Belfort

Stand in front of a CNC machine for 5 min (when it is working!) andthen in from of a AM machine for 5 min. You will find out which is fast!That is why we do not call it RP any more!!

Allied Technologies (Pre/In situ/Post Build)Challenges in AM: Slow



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RP

Indirect Processes

All AM materials areproprietary andexorbitantly priced (40-60%)

Exorbitantly pricedequipment in order torecover IP fast.

AMhas linearity of cost(& time) with quantity.

Allied Technologies (Pre/In situ/Post Build)Challenges in AM: Linearity of cost & time



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Quality i. Exterior or surface - Surface finish- Accuracy

ii. Interior or matrix - Composition

- Limited range of each process

- Proprietary

- Homogeneity (inherent anisotropy, porosity& residual stresses)

Cost Linear!

Time Time to build Not rapid enough!

- Number of layers- Sacrificial support

Life Low life due to- Poor quality- Degeneration over time

Allied Technologies (Pre/In situ/Post Build)Challenges in AM: Summary



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ed ec o og es ( e/ s tu/ ost u d)Challenges in AM: Summary

The usefulness of AM is amplified manifold by through appropriatepre/in-situ/post-build processes to overcome their limitations.

Pre-build processes In-situ build processes Post-build processes

Reverse Engineering

Model processing: Datareduction, splitting largepieces along with jointsfor gluing, editingmodels, repairing

models, lattice structure

Analysis andoptimization (OptiLOM)

Embedding PCB, insertsetc.

Cold working after everylayer

Machining in-between a

certain number of layers

Improving surface quality(polishing, machining)

Improving interior quality(Thermal and/or pressuretreatments)

Multiple pieces and/or ofdesired material throughindirect routes (vacuumcasting, metal casting)

Additive Manufacturing + Allied Technologies = Rapid Manufacturing



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g ( )Exterior improvements: Liquid polishing

Micro-Machining of

BestinClass, Swiss



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g ( )Interior improvements: Hot Iso-static Pressing (HIP)

Powder-based RP (laser/EBsintering or bonding) is notstrictly PM as compacting ismissing. Powder-basedmetallic AM processes

invariably have some micro-porosities which reduce theirfatigue life required inaerospace. HIP makes themas strong as machined or

forged components.



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g ( )Interior improvements: Hot Iso-static Pressing (HIP)

Job size Max pressure Max temp.DMRL 650mm dia x 1200mm long 2000 bar 1440C/ 2000C

VSSC 500mm dia x 1000mm long 2000 bar 1440C

TVSSmall (for the casing ofturbo-charger))

2000 bar 1440C

Leak proof joints and valves are critical in HIP. This was a restrictedtechnology a few years ago. Very recently, ASACO, Secundarabad,started offering these machines. Three of their machines are inIndia:

It costs around Rs. 30 crore.



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g ( )Indirect Processes: Investment Casting (QuickCast)

Courtesy: Bajaj Auto,India

Courtesy: Mercedes-Benz

Knee implant

3D Systems SLA mchineproduces quasi-hollowpatterns. Note that:

QuickCast uses flaskinvestment casting.

Of late, SLSs densepolystyrene patterns arereplacing this.

the honeycomb structure isachieved using QuickCastbuild style and no specialgeometric pre-processing is

required. Hollowness is not for saving

material or speed but toavoid shell cracking.



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g ( )Indirect Processes: Investment Casting

Magnesium Sealhousing of Kaveri

engine (GTRE,Bangalore) made by

Aerocast, France



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Indirect Processes: Investment Casting

Indigenous Efforts in Rapid Casting (Aluminium)

GTRE, Bangalore, IIT Bombay, CTR, Ludhiana and PTC, Lucknow



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Ice

Slurrycoating

Pressure & Temp.Controlled Environment(Controlled Vacuum Freezer)


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Rapid Manufacturing (RM)


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RM = AM + Allied Technologies

MetallicRM

Subtractive

Hybrid

Additive

CNCMachining

LaminatedManufacturing

Powder-bedTechnologies

DepositionTechnologies

RapidCasting

DirectRoutes

IndirectRoutes

WithoutPatterns

WithPatterns

Additive SubtractiveNon-

ConsumableConsumableBonding FusionSintering

Laser EB Arc Unlike the layered mfg approach of RP, RMwould require multi-facetedand hybridapproaches to meet the varied needs ofmaterial, quality, quantity, cost etc.

Matl. Geom.

SRM Best Best

LM Ok Ok

HLM Ok Best

RC Best Ok

1 2 3

4

5

6


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Conclusions


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Conclusions

The divide & conquer approach of AdditiveManufacturing (AM)led to total automation. This revolutionized the way products aredesigned and manufactured today.

The same divide & conquer approach is responsible for thepathetic quality, short life, long production timeand high cost.

These bottlenecks can be overcome by adopting appropriate alliedtechnologies which are pre-/in-situ/post-build processes. Thesetogether are known as Rapid Manufacturing (RM).

We need to adopt HYBRID approaches for immediate and nearfuture needs. They may be [addition, subtraction], [bonding,fusing], [Arc, Laser, EB], [2.5 ax, 3-ax, 5-ax], [Direct, Indiect]

Conclusions


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Conclusions

The special geometric and material features of RM gives greaterdesign freedom which are yet to be exploited.

RM exists for any situation. So (a) their appropriate selection and(b) Design for RM are essential for efficient product development.

Thank You!


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Thank You!K.P. Karunakaran

Professor

Department of Mechanical EngineeringIndian Institute of Technology Bombay

Powai, Mumbai-400076, INDIA

Tel.: 022-25767530/ [email protected]

www.me.iitb.ac.in/~karuna


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Classification of AM Processes


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1. Vat Photo-polymerizationprocess

SLA, Envisiontec DLP, Micro-SLA

2. Material jetting process(single & multi nozzles)

Objet

3. Binder jetting process

3DP (Zcorp, ExOne)

4. Material extrusion process

FDM

5. Powder-bed fusion processS(L/EB)S

6. Sheet lamination process

LOM, UC

7. Directed Energy Depositionprocess

FDM

Classification of AM Processes


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AM Research in IIT BombayResearch Interests


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1994

2015

2000

2005

2010

OptiLOM

Optimization of Machining through Simulation (G) and Modeling (M)

Hybrid Layered Manufacturing (HLM)

Rapid Casting & Large Prototyping

RW MAV

Tail-less Heli(multi-rotor & Tip-

jet)

Research Interests

Nandi (Holy Cow of Isha)Reverse Engineering + Jugadu (ingenuity)


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Dim: 10 ' x 20' x 15'

Material: MS

Weight : 22 Tons

Project duration: 6-8months

Method used: 1/6thPOPand WAX models.

Scanned usingHandyscan. Built throughjugadu.

Reverse Engineering + Jugadu (ingenuity)

Documents

20131022-Additive Manufacturing & Allied Technologies, Pune