Data-Driven Modeling for Additive Manufacturing of Metals Proceedings of a Workshop (2019) / Chapter Skim
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4 Process and Machine Design
4 Process and Machine Design
Pages 28-40
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, L Jian Cao (Northwestern University) , Ranadip Acharya (United Technologies Research Center)
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After these parameters are defined, it is time to move to the process selection phase, which includes processing, monitoring, and control. After this phase, there should be enough information for postprocessing practices such as unpacking, part cleaning, stress relief, part removal, support removal, heat treatment and hipping, surface finishing, and part inspection.
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1 Example machines include the Selective Laser Melting Machine 280, Matsuura LUMEX, DMG Mori LASERTEC 65, Friction surface AM Aeroprobe, BeAM Modulo 400, FDM Fortus 450mc, and Polyjet Stratasys j750.
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PROCESS AND MACHINE DESIGN 31 TABLE 4.1 Available AM Processes and Equipment Process Process or category technology Material Manufacturer Machine Vat photo- Stereolithography Ultraviolet Asiga Freeform Pico polymerization curable resins 3D Systems iPro, Projet6000/7000 EnvisionTEC Perfactory Rapidshape S Series Waxes DWS DigitalWax Ceramics Lithoz CeraFab 7500 Material Multijet Ultraviolet 3D Systems Projet 3500 jetting modeling curable resins HD/3510/ 5000/5500 Stratasys Objet Waxes Solidscape 3Z Binder jetting 3D printing Composites 3D Systems Z Printer Polymers, Voxeljet VX Series ceramics Metals ExOne M-Flex Material Fused deposition Thermoplastics Stratasys Dimension, Fortus, extrusion modeling Mojo uPrint MakerBot Replicator RepRap RepRap Bits from Bytes 3D Touch Fabbster Fabbster Kit Delta Micro UP Factory Corp. Beijing Tiertime Inspire A450 Waxes Choc Edge Choc Creator V1 Essential Imagine Dynamics Fab@Home Model Metal nScrypt 3DnþnMill Three axis CNC machine Hyrel 3D Hydra 340, 640, 645 3-axis CNC machining and laser cutting continued
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32 ADDITIVE MANUFACTURING TABLE 4.1 Continued Process Process or category technology Material Manufacturer Machine Powder-bed Selective laser Thermoplastics EOS EOS P fusion sintering Blueprinter Selective heat sintering 3D Systems sPro Metals 3Geometry DSM Matsuura Lumex Avance-25 and 60 3-axis CNC machining controlled atmosphere Selective laser Metals 3D Systems/ PXL, PXM, PXS melting Phenix EOS EOSINT M SLM Solutions SLM Concept Laser LaserCusing 3D Systems ProX Electron beam Metals Realizer SLM melting Renishaw AM250 Arcam Arcam A2 Sciaky DM Sheet Laminated object Paper Mcor Technologies lamination manufacturing polymers Matrix 300þ Metals Fabrisonic SonicLayer Thermoplas- Solido SD300Pro tics
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SOURCE: Tahany El-Wardany, United Technologies Research Center, presentation to the workshop, October 25, 2018. CURRENT STATE OF COMMERCIAL POWDER-BED ADDITIVE MACHINES -- AM MACHINE DESIGN ISSUES IMPACTING BUILD-TO-BUILD AND PART-TO-PART VARIABILITY Ade Makinde, General Electric Global Research Center, with support from Johannes Henrich Schleifenbaum, Fraunhofer Institute for Laser Technology, and Shoufeng Yang, KU Leuven Makinde described GE Additive, which was launched in 2016 and includes divisions such as AddWorks™ consultancy, machine odalities, m advanced powders and coating materials, software, and customer experience centers.
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; • Galvo, the laser power and scanning mirror speed control; • Inclination of the scan angles (as build chamber size increases) ; • Thermal lensing, especially for long duration builds; • Fumes, which can be detrimental to the laser systems; • Laser wavelength, which typically needs to be suitable for differ ent materials; and • Hatch pattern.
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MODELING CHALLENGES AND OPPORTUNITIES AT THE PART LEVEL Jian Cao, Northwestern University, with support from Ranadip Acharya, United Technologies Research Center, and Mustafa Megahed, ESI Group Cao began by explaining the needs for simulations on process planning (e.g., choosing the best strategy) and material property prediction.
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Cao showed the critical length scales for AM products and their correspondingly normalized values for part length scales (see Table 4.2) and the critical time scales in building and using AM parts normalized with the build time scales (see Table 4.3)
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TABLE 4.3 Scales for Different Simulations at Normalized Time by That at the Build Scale Critical time scale Normalized time by (sec) that at the build scale Part life 107 – 109 ~104 – 107 Build time 102 – 104 1 Layer time 100 – 102 ~102 – 103 Solidification time scale 10–4 – 10–3 ~10–6 Thermal diffusion time scale 10–5 – 10–3 ~10–7 Thermal convection time scale 10–5 – 10–4 ~10–7 NOTE: Blue shading indicates desired to be simulated; green shading indicates needed at part level; orange shading indicates currently not simulated at the part level.
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Multiscale simulation tools can be developed to fully integrate or pass the critical and equivalent data from the fine scale model that incorporates detailed physics to the course scale. An audience member wondered how the graphics processing units available in many current machines would affect the types of simulations that could be done.
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Some cases have shown that blue lasers can increase productivity tenfold in welding. Yang stated that green laser technology still needs to be improved to enable selective laser melting.
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2019. Acceleration strategies for explicit finite element analysis of metal powder-based additive manufac turing processes using graphical processing units.
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