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ADDITIVE MANUFACTURING (EXERCISE 2)

TEAM LE FRECCE (GROUP #5)

Aditya Chaudhary (1846481)

Akshay Dhalpe (185686)

Sandeep Gupta (1844011)

Sandeep Goud (1873893)

PROF. ALBERTO BOSCHETTO

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OBJECTIVE

  • To fabricate two small batches of sun-glasses via FDM having a specific surface roughness requirement value in the following table:

2

Group

Machine

Batch 1

Scale batch 1

Batch 2

Scale batch 2

Ra max

5

1200

15

1,1

10

0,75

red surface 30 μm

Sequence

1

2

3

4

5

6

7

The steps of AM processes

3D solid model creation

Conversion to the STL format

Computer Aided Manufacturing

STL slicing and check

Support generation

Toolpath generation and physical fabrication

Post processing

Data

Given

Given

To Do

To Do

To Do

To Do

To Do

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COMPUTER AIDED MANUFACTURING: SELECTION OF PROCESS PARAMETERS

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FDM PROCESS OVERVIEW� ��

Fused Deposition Modeling is an AM technology, where we use material extrusion process. Here we use ABS material, that is deposited in layers with required thickness. Fused material is spread continuously on the platform using nozzle. Interior solid area and support structure is filled using some fill-strategy. Part is oriented in best way to satisfy the production rate, time and cost.

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MACHINE SELECTION

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MATERIAL SELECTION

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PART ORIENTATION SELECTION

  • Based on the requirement to fabricate 2 batches of 2 different scales, we decided to distribute them to fully utilize the space.
  • Chamber 1 and 2 distribution is in the next page and please ignore extra numbers representation.

CHAMBER

BATCH 1

BATCH 2

1

10

0

2

5

10

TOTAL FABRICATED

15

10

MODEL MATERIAL (cubic cm)

196.3

240.08

SUPPORT MATERIAL (cubic cm)

873.99

973.51

TIME (min)

102:12:00

102:18:00

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CHAMBER DISTRIBUTION

CHAMBER 1

CHAMBER 2

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PART ORIENTATION SELECTION

We checked various orientation angles and found the following orientation coupled with 0.3302 mm layer thickness as the most economic solution.

  • First, we compared all possible orientations and found the orientation of 90° about y-axis as the optimized parameter (highlighted in pink color).
  • Secondly, we compared this optimized values with the layer thickness of 0.3302 mm highlighted in green color).

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Orientation Angle

Build Time Estimate (min)

Model Material (cubic cm)

Support Material (cubic cm)

Layer Resolution (mm)

Default

5:03

18.321

43.031

0.254

180° in x dir

4:27

18.339

33.135

0.254

90° in x dir

4:54

18.065

26.45

0.254

270° in x dir

10:59

18.016

138.331

0.254

90° in y dir

10:13

24.007

97.295

0.254

90° in y dir

7:36

23.905

98.571

0.3302

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HEAD TEMPERATURE SELECTION

    • 270° for ABS

Extrusion Head

    • 110° for ABS

Build Platform

    • 75° for ABS

Build Room

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MODEL INFILLING SELECTION

First raster layer of glass

Final raster layer of glass

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AUTOMATIC SUPPORT DESIGN

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DEPOSITION ANGLE

We can find the deposition angle from the Gauss’s Theorem but there are infinite normal vectors so in this case we approximate the angle.

We constructed 3 random normal vectors with the help of parallel planes of 3 distinct surface triangulations on red surface and approximated the average to be 89º.

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SURFACE ROUGHNESS

Optimum deposition angle that we used is 89°. The roughness obtained for red area is of 22 µm and dimensional deviation range found to be (-0.03 to 0.06) mm.

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THE END