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Design for Addit ive Manufacturing
National Laboratory for Addit ive Manufacturing, 3D Digit izat ion and Computed Tomography, Mexico
June 2017
Leopoldo Ruiz-Huerta, Adriana Hernández-Contreras, A. Horacio Gutiérrez-Osorio, Luis Sánchez-Balanzar
1
Out look1. What is design?
2. Why design for Addit ive Manufacturing DFAM?
3. Conclusions
2
Addit ive Manufacturing
General term for those technologies that based on geometrical representat ion create physical objects by successive addit ion of material.
While 3D print ing refers to technologies which requires print ing head, nozzle or another printer technology.
Usually refers to low end technologies.
ISO/ASTM 52900:2015
3
What is design?
Think about shapes
a) Etley point
b)Kings corner notched point
c) Graham cave point
4
a) b) c)
Source: http://associations.missouristate.edu/mas/identification.html
Think About Materials
a) Obsidian
b)Bronze
c) Bone
d)Wood
e) Steel
5
a)
b)
http://www.metmuseum.org
e)
http://www.knivesbynick.co.uk
http://www.metmuseum.org
c)
http://www.alltribes.com
d)
http://www.historymuseum.ca
What is design?
Think about process
6
Forge arrowheadSource: Youtube
Sculpt ArrowheadSource: Youtube
Craft arrowheadSource: Framepool.com
What is design?
Think about performance
a) Firebox head: It was used to cause fires in cit ies, fortresses, ships, etc. from distance.
b)Bodkin head:Perfect to pierce cuirasses and chain mails.
c) Barbed head: Used on large game such as boar or deer. Used in war to hurt enemy horses.
d)Broadhead: Their function is todeliver a wide cutt ing edge so as tokill as quickly as possible
7
a) b)
c) d)
http://www.arcomedievo.es
What is design?
What is design?
The engineering design process is a formulat ion to assist in creat ing a something.
The engineering design is defined as component, or process to meet desired needs.
It is a decision making process (often iterat ive) in which the basic sciences, mathematics, and engineering sciences are applied to convert resources opt imally to meet a stated object ive
8Tayal, S. P. Engineering design process. of Computer Science and Communication Engineering (2013).
9SOURCE: Shimelis Mutera. Production & opeartions management. 2014.
What is design?
More design process less manufacturing worries
Relat ively early in the design act ivity the decisions taken will commit the operat ion to cost which will be incurred later
10SOURCE: Shimelis Mutera. Production & operations management. 2014.
What is design?
Design For “X”DFX research emphasizes the considerat ion of all design goals and related constraints in the early design stage. Includes:
Design for assemblyDesign for manufactureDesign for disassembly and design for recyclabilityDesign for environmentDesign for life-cycleDesign for qualityDesign for maintainabilityDesign for reliability
11Design for manufacture and design for ‘X’: concepts, applicat ions, and perspect ives, Kuo TC, Huang SH, Zhang HC, Comput Ind Eng, 2001
What is design?
Out look1. What is design?
2. Why design for Addit ive Manufacturing DFAM?
3. Conclusions
12
Addit ive manufacturing has unique capabilit ies:
● Design flexibility: AM enables thecreat ion of almost any complexgeometric shape.
● Cost of geometric complexity: Whenemploying AM, this complexity comes atno addit ional cost, as there is no needfor addit ional tooling, re-fixturing,increased operator expert ise, or evenfabricat ion t ime.
. 13
Additive Manufacturing: SASAM Standarization Roadmap 2015
DFAM
● Reduce need of assemblage: AM processesenable the product ion of geometric shapes thatwould otherwise require assembly of mult ipleparts.
● Reduce material waste: Creating products layer-by-layer is inherent ly less wasteful thantradit ional subtract ive methodsof product ion.
● Customized unique items: Current embodimentsof AM technologies are suitable for fabricat ion ofproducts that feature customized features.
14
Source: The Economist, 2009
Source: AM Magazine, 2015
DFAM
● Immediate availability of CAD models: Designs in the form of digital filescanbe easily shared, facilitat ing the modificat ion and customisat ion ofcomponentsand products
● Reconfigured value chains: Shorter and simpler supply chains,more localisedproduct ion, innovat ive distribut ion models,and new collaborat ions.
15
Source: The Economist, 2009
DFAM
● Time and cost efficiency in product ion run: While AMprocesses are significant ly slower than inject ion moldingfor fabricat ing components, they are better suited forlow part quant it ies as there is no startup tooling requiredfor product ion.
● On-demand and on-locat ion AM product ion can lowerinventory costs and potent ially reduce costs associatedwith supply chain and delivery.
● Small batches: It ’s very cost ly to create molds andproduct ion lines for small batches by tradit ionaltechniques. 16
http://3dprintboard.com
DFAM
There are some issues that AM should overcoming:
● Dimensional accuracy: There is an increased need forestablishing industrial dimensional accuracy standardsfor AM.
● Surface quality: the quality of a printed part’s surfaceis mainly determined by the thickness of each printedlayer
17
https://www.3dhubs.com
http://www.popularmechanics.com
DFAM
● Limited amount of materials: Whileconsumer goods are comprised of a widevariety of materials that render differentbehaviors and funct ionalit ies, thematerial select ion of AM systems isquitelimited.
● Size: Some of the building size of AM technologies is less than tradit ional processes (inject ion, milling, etc.)
18
https://nutz95.wordpress.com
DFAM
● Mechanical Performance: Unfortunatelythe strength and the st iffness ofcomponents built by these technologiesare not part icularly high and,furthermore, they are difficult to bedefined due to their internal structurescan exhibit one or more of the nextimportant features:
19
Dawoud, M., Taha, I., & Ebeid, S. J. (2016). Mechanical behaviour of ABS: An experimental study using FDM and injection moulding techniques. Journal of Manufacturing Processes, 21, 39-45.
Heterogeneity
Anisotropy
Discontinuity
DFAM
20Density vs. Young´s modulus for A.M. Materials. SOURCE: Spadaccini. Engineering properties only previously theorized.
"By controlling the architecture of a microstructure, we can create materials with previously unobtainable properties in the bulk form."Chris Spadaccini
DFAMMechanical propert ies performance of materials used in A. M.
21Mechanical properties of metallic materials – minimum values from data sheets. SOURCE: Metal AM magazine 2017.
Mechanical propert ies performance of materials used in A. M.
DFAM
Mechanical propert ies performance of materials used in A. M.
22SOURCE: Gianluca Cicala, et. al.. Engineering thermoplastics for additive manufacturing: a critical perspective with experimental evidence to support functional applications. 2017.
DFAM
Building orientat ion.
The bed building is a horizontalsurface where the first layer isattached, the piece is manufactured inthe Z axis whereas the shape ispatterned in the XY plane.
To manufacture the piece it isnecessary to set what side will be theinit ial layer, the piece will increasefrom that layer.
23Source: Scielo.org
DFAM
24
Zhang Yicha, 2016
DFAM
25SOURCE: Metal AM: The "Materials" ALM & Mechanical Properties: It’s All About Powder Metallurgy! (1/2)
Interdependence of mechanical properties, microstructural characteristics and selective melting
DFAM
26
a) Dependency of the structure on the procedural parameters; b) Procedure of the powder laser scanning.
I. No melting.II. Partial melting.III. Melting with the
balling phenomenon.
IV. Complete melting
SOURCE: Pavel Hanzl, et. al. The Influence of Processing Parameters on the Mechanical Properties of SLM Parts. 2014.
DFAM
27SOURCE: Agnes Bagsik, Volker Schöppner. Mechanical properties of fused deposition modelling parts manufactured with ULTEM*9085. 2011.
Different result when varying parameters (raster angle and air gap) for thin and thick filaments in FDM
DFAM
28
Six different organizations participated in a interlaboratory study to quantify the variability in the tensile properties of Inconel 625 specimens manufactured using laser powder bed fusion-additive (LPBF) manufacturing machines.Different machine settings that may have affected the mechanical properties of the tensile specimens and thus affected the variability of the results.
SOURCE: Brown, et.al. Interlaboratory Study for Nickel Alloy 625 Made by Laser Powder Bed Fusion to Quantify Mechanical Property Variability. 2016.
DFAM
Post-processingWhat is post-processing?Post-processing is the final stage of addit ive manufacturing. It ’s the last step in the manufacturing process, where parts receive finishing touches such as: post-curing, smoothing, paint ing, post-hardening, Hot Isostat ic Pressing, etc. 29SOURCE: Sunpreet Singh, et. al. Material issues in additive manufacturing: A review. 2016.
DFAM
Why is post-processing important?
Post-processing improves the quality of parts and ensures that they meet their design specificat ions. The finishing process can enhance a part ’s surface characterist ics, geometric accuracy, aesthet ics, mechanical propert ies, and more. For samples and prototypes, this can mean the difference between a sale or a loss. For product ion parts, finishing creates a part that is ready to use.
30SOURCE: Sunpreet Singh, et. al. Material issues in additive manufacturing: A review. 2016.
DFAM
31
Electron Beam Melting (EBM)
Direct Metal Laser Sintering (DMLS)
Selective Laser Sintering (SLS)
Fused Deposition Modeling
(FDM)
Polyjet SLA
Finish machining, polishing, tapping & chasing, wire & sinker EDM, slurry honing, ultrasonic cleaning, heat treating, hot isostatic press, anodizing, chem film, welding, brazing, insert and helicoil installation
Finish machining, polishing, tapping & chasing, wire & sinker EDM, slurry honing, painting, ultrasonic cleaning, H900 heat treating, solution heat treating, precipitation heat treating, hot isostatic press, anodizing, chem film, welding, brazing, insert and helicoil installation.
Nickel over copper plating, EMI, dying, painting, sealing / infiltration, tumbling, chrome plating, vacuum metalizing, hole tapping, threading, insert or helicoil installation, machining, assembly.
Nickel over copper plating, EMI, painting, dyeing, sealing / infiltration, chrome plating, vacuum metalizing, tapping, threading, insert or helicoil installation.
Painting, soft touch, light assembly
Nickel over copper plating, chrome plating, vacuum metalizing, painting, soft touch, polishing, tapping, threading, insert or helicoil installation, pad printing.
DFAM, Post-processing
32
The impact of post-processing
PRIMARY ISSUES SECONDARY ISSUES
EnergyTimeCost
QualityStaffing
FacilitiesSafety
Hybrid Manufacturing
Hybrid manufacturing = Addit ive Manufacturing + Subt ract ive process and / orForming process
33SOURCE: Aerospace. Manufacturing and design. Magazine. August 2016.
Hybrid completes the spectrum of options between pure additive & pure subtractive
34
Uncertainty caused by process and material variables
Process variables:Layer thickness,
raster width, laser power, scan velocity,
chamber temperature, orientation part, etc.
Material variables: Density, heat
capacity, Tg, critical exposure, depth of penetration, etc.
What is the performance of the final part for a defined
geometry?Tensile strength, Young´s
modulus, hardness, flexural strength, etc.
DFAM
35Assembly Based Methods to Support Product Innovat ion in Design for Addit ive Manufacturing: An Exploratory Case Study, Laverne F,Segonds F, Anwer N, Le Coq M, J Mech Des, 2015
DFAM
36Assembly Based Methods to Support Product Innovat ion in Design for Addit ive Manufacturing: An Exploratory Case Study, Laverne F,Segonds F, Anwer N, Le Coq M, J Mech Des, 2015
DFAM
There is a strong relat ionship betweengeometry and performance of a part of adevice. Determinat ion of this geometry isone of the cores into the design process.
Like in the tradit ional design process, indesign for AM final shapes of a device andits parts are strongly t ied with theirapplicat ion and function.
37
Geometry
https://www.quora.com
DFAM
38
Process Material Geometry
Structure(properties)
Together with process and material employed to made thepart, geometry generate an specific structure with specificpropert ies.
DFAM
39
Performance
Structure(properties)
External estimuli
Conditions of use
Finally, performance of structure is determined by the external st imuli(e.g. loads) and the condit ions of uses(e.g. temperature)
DFAM
Thanks to the AM process now is possible manufactureparts and devices with complex geometries if is neededto accomplish the function requirements.
40
Topology optimization is a numerical tool that allowfrom a given predefined design domain, some givensupports in connection to the design domain, somegiven external loads, and a given material to be used,designing an optimal structure to carry the given loads.This should be done by finding the optimal subdomain,of the given design domain, to fill with material.
https://s-media-cache-ak0.pinimg.com
DFAM
41
Topology Optimization from existing designSorce: www.linkedin.com
The object ive might be to minimize the total weight of the structuresubject to constraints on displacements and stresses in the structureunder the given loads
DFAM
● Lat t ices and AM: The concept ofdesigned latt ice structures is motivatedby the desire to put material only whereit is needed for a specific applicat ion.From a mechanical engineeringviewpoint, a key advantage offered bylatt ices is high strength accompanied bya relat ively low mass.
● Latt ice structures tend to have complexgeometry variat ions in threedimensions, which by tradit ionalprocessesishard to make or impossible.
42https://www.underarmour.com/en-us/3d-architech
] J. Nguyen, S.-I. Park, D. W. Rosen, L. Folgar, and J. Williams. Conformal lattice structure design and fabrication. 23rd Annual International Solid Freeform Fabrication (SFF) Symposium, pages 138 – 161, 2012. Austin, Texas
DFAM
43
Numerical and analyt ic methodshas been employed to characterizeparts made by AM, however unlikewhat tradit ional process exhibit ,parts made by AM process withsame material and geometry asformer show internal structureswith complex geometries.Therefore is necessary add thisfeatures in the analysis.
Imágenes mediante SEM de la superficie de fractura de piezas hechas a) por inyección b) mediante FDM sometidas a tensión. Dawuld et al. 2016
DFAM
Finite element method allow simulate physical mechanical test, t ieing specific features presents in AM processes: heterogeneity, discontinuity and anisotropy
44
DFAM
Non-Destruct ive testsNon-destruct ive tests are techniques for inspect ion andquality assurance. To analyze the integrity of material,componentsor structures*.
In Addit ive Manufacturing allow to inspect the innermicrostructure maintaining itsshape.
A commonly tool is Computer Tomography to inspect thiskind of pieces.
45*Cantatore, A., & Müller, P. (2011). Introduction to computed tomography. Kgs.Lyngby: DTU Mechanical Engineering.
DFAM
Computed Tomography has been widely used to inspect inner features in AM pieceslike microcracks and porosit ies*.
In Material Extrusión is used to analyze the rasters and how they come together^ .
46* Siddique, Shafaqat, Muhammad Imran, Miriam Rauer, Michael Kaloudis, Eric Wycisk, Claus Emmelmann, and Frank Walther. 2015. “Computed Tomography for Characterization of Fatigue Performance of Selective Laser Melted Parts.” Materials & Design 83 (October): 661–669. doi:10.1016/j.matdes.2015.06.063.^ Nouri, H., Guessasma, S., & Belhabib, S. (2016). Structural imperfections in additive manufacturing perceived from the X-ray micro-tomography perspective. Journal of Materials Processing Technology, 234, 113–124. http://doi.org/10.1016/j.jmatprotec.2016.03.019
SLM CT Pore Analysis*
DFAM
47
CT Pore Analysis a) FDM, b) Polyjet, c) SLA
DFAM
Standard tensile tests method is used to determinemechanical propert ies from the curve Strain - Deformationas a function of the build and raster orientat ion [*].
Differents build orientat ions gives a different values intheir mechanical propert ies such as their Young’s Modulus.The common analysed orientat ion are: Flat , Edge andUpRight [^].
The test pieces are design based on the ASTM norm D638[+].
48* Cantrell J. et al. (2017) Experimental Characterizat ion of the Mechanical Propert ies of 3D Printed ABS and Polycarbonate Parts. In: Yoshida S., Lambert i L., Sciammarella C. (eds) Advancement of Opt ical Methods in Experimental Mechanics, Volume 3. Conference Proceedings of the Society for Experimental Mechanics Series. Springer, Cham^ Es-Said, O. S., J. Foyos, R. Noorani, M. Mendelson, R. Marloth, and B. A. Pregger. 2000. “Effect of Layer Orientat ion on Mechanical Propert ies of Rapid Prototyped Samples.” Materials and Manufacturing Processes15 (1): 107–122. doi:10.1080/10426910008912976.+ASTM. 2010. “ASTM D638.” D638. PA, USA: ASTM Internat ional.
DFAM
Piece builded in Edge orientat ion shows the better values in tensile test*.
Pieces builded in Flat and UpRight orientat ion shows similar mechanical propert ies*.
Raster angle also affects the mechanical propert ies, surface roughness and processcost*.
49*Durgun, Ismail, and Rukiye Ertan. 2014. “Experimental Invest igat ion of FDM Process for Improvement of Mechanical Propert ies and Product ion Cost .” Rapid Prototyping Journal 20 (3): 228–235. doi:10.1108/RPJ-10-2012-0091.
Broken test piece*
DFAM
How to achieve a more energy-saving addit ive manufacturing?
50
Energy consumption (J/m3, J/kg)
Material and process: parameters,
physical and chemical properties
Peripheral elements:Chamber, rollers,
drivers, coolers, etc.
Performance (mechanical, electrical,
optical, thermal, etc. properties
DFAM
GE Aviation recently challenged the additive manufacturing community to redesign a titanium aircraft engine bracket and received hundreds of entries from 56 countries. The winning part designed by M Arie Kurniawan is shown above. The original bracket weighed 2033 grams (4.48 pounds), but Kurniawan was able to slash its weight by nearly 84% to just 327 grams (0.72 pounds) (Courtesy GrabCad).
SOURCE: www.geaviation.com
51
Out look1. What is design?
2. Why design for Addit ive Manufacturing DFAM?
3. Conclusions
52
ConclusionsDFAM guidelines are not yet ready but has two major direct ions:
Using of opportunit ies allowed by AM
Integrat ing the restrict ions inherent in AM
53
