Rapid Prototyping & Manufacturing. ENGI 7928 Computer-Aided Engineering

Transcription

1 Rapid Prototyping & Manufacturing

2 Outline Why RP&M Technology? Basic Principles Currently Available/Developing Systems Directions for RP&M Research

3 R&D Directions in Manufacturing Intelligent Manufacturing Control Equipment Reliability & Maintenance Advanced Materials Product Realization Education & Training

4 Product Realization Multidisciplinary Concurrent, life cycle design teams Intelligent product models Common databases across all functions (eg. engineering, planning, marketing,...) Management of PRP Time to market is critical and prototypes used to aid communication

5 How do we make complex things?

6 History of Prototyping Artist/Craftsperson created model Development of CAD -> virtual models CAD databases used to generate CNC programs. Subtractive processes. Development of additive processes... generally called Rapid Prototyping.

7 And the future?

8 Definition A process by which a solid physical model of a part is made directly from a 3-D CAD drawing without unique tooling or fixtures. Referred to as Desktop Manufacturing Automated Fabrication Tool-less Manufacturing Free-form Fabrication

9 Goals of Rapid Prototyping Substantially reduce product development time, through rapid creation of 3D models. Improve communication (visualization) within multidisciplinary design teams. Address issues of increased flexibility & small batch sizes, while remaining competitive (rapid manufacture).

10 Basics Require a geometric model. Must include surface information. Usually solid modeling system: CATIA, I-DEAS, Pro/Engineer, SolidWorks, etc Surface models require completely bound volume and internal detail.

11 Basics (continued) 3D geometric model is mathematically sectioned into parallel cross-sections. Each cross-section creates a 2D binding or curing path for model construction. Models are constructed one layer at a time until complete. Supports may be required. Two stages: Data preparation and model production.

12 Data Preparation CAD data converted to.stl format..stl designed for 3D Systems Inc. Stereolithography Apparatus (SLA). Triangular facets are used to describe the shape of a closed 3D model. Faceted surface must be completely bound. Curved surfaces are approximated.

13 .STL Format Developed by Albert Consulting Group Consists of x, y & z coordinates of triangles Example: solid... facet normal outer loop vertex vertex vertex endloop endfacet... endsolid

14 .STL Format (continued) All adjacent triangles must share two vertices. Translation software is either included in CAD package or third party. Translator should provide ability to adjust chordal deviation (ie. trade-off accuracy vs file size and processing time).

15 VRML vs.stl Virtual Reality Modeling Language Developed through Silicon Graphics using their Open Inventor (.iv) standard. Lead to Tele-Manufacturing as proposed by Michael Bailey, U. of C., San Diego Take advantage of greater development effort and utilize other features (e.g.. colour, colour gradient, texture). STL still the dominant RP format

16 RP Production Technologies Stereolithography Apparatus presented at Autofact show in November, Currently upwards of twenty different technologies being developed/marketed. Major differences in materials used and build techniques. Various RP technologies outlined in following slides.

17 Stereolithography Apparatus (SLA) - 3D Systems Laser generated ultraviolet beam traces out cross-section & solidifies liquid polymer. Component is built in vat of liquid resin. Vat size limits prototype SLA-190 (7.9 x 7.9 x 9.8 ) US$105,000 SLA-250 (10 x 10 x 10 ) US$210,000 SLA-250 (20 x 20 x 24 ) US$420,000

18 Stereolithography Apparatus ENGI 7962 Computer-Aided Engineering

19 Stereolithography (cont.) Materials at least five currently available. All are acrylates (non-reusable thermosets). Accuracy - ranges from 0.1% to 0.5% of overall dimension from small to large parts. A very accurate RP technology. Curing stability and support structures remain challenges.

20 Solid Ground Curing / Photomasking - Cubital Ltd. Uses photo-masking to solidify whole layers of photopolymer at one time. Solider 5600 (20 x 14 x 20 ) US$550,000 with machine dimensions 13.5 x 5.5 x 5 Layer thicknesses of and dimensional accuracy of 0.02, building up to 100 layers/hour.

21 Solid Ground Curing (cont.)

22 Solid Ground Curing (cont.) Full cure as built minimizes shrinkage and eliminates post-curing. Wax eliminates need for supports. Fly cutter provides for undo operation. System produces a lot of waste. Can t reuse material picked up during milling, and uncured resin is a hazardous material.

23 Selective Laser Sintering - DTM Corp Developed at U. of Texas at Austin Utilizes powder, rather that liquid polymer. Potential exists for different materials including polycarbonate, PVC, ABS, nylon, polyester, polyurethane and casting wax. Sinterstation 2000 (12 dia. x 15 dp) US$425,000. Builds.4-2 per hour.

24 Selective Laser Sintering (cont.) ENGI 7962 Computer-Aided Engineering

25 Selective Laser Sintering (cont.) Layers from thick. Accuracy from.005 to.015 depending on size. Components can be recycled by crushing and converting back to powder. Research is going into materials such as powdered metals, ceramics and composites.

26 Laminated Object Manufacturing Process uses bonded sheet material. Normally paper, but metals, plastics and composites are possible. LOM-1015 (14 x 15 x 10 ) US$95,000 LOM-2030 (30 x 20 x 20 ) US$180,000 Sheets of thick. Accuracy of +/ achievable.

27 Laminated Object Manuf. (cont.)

28 Laminated Object Manuf. (cont.) Support provided by remainder of sheet. Prototypes less fragile than polymers. No internal stresses or curing shrinkage. Paper waste is non-hazardous. Machine can be operated in an office environment. Cannot build hollow cavities as single part.

29 Three Dimensional Printing - MIT Utilizes powdered material, spread out one layer at a time. Adhesive is applied in droplets through a device similar to an inkjet printer head. Limited quantitative data available on accuracy. 3DP licensed to Soligen Inc. for Direct Shell Production Casting process.

30 Three Dimensional Printing (cont)

31 Three Dimensional Printing (cont.) Internal supports not required. May require post processing, depending on material and binder. Work continues on limiting impact of binder drops, reducing jagged print edges and flow control for the binder. Consortium includes Boeing, Hasbro, Johnson & Johnson, 3M & United Tech.

32 Other RP Systems How good is your imagination?

33 Other RP Systems Fused Deposition Modeling - Stratasys uses.050 dia. thermoplastic filament Ballistic Particle Manufacturing - BPM uses three axis robotic system controlling an ink jet like deposition head. Low cost, easy to operate system. Electrosetting - U.S. Navy 2D profiles are used to plot electrode shapes which are attached to foil. Multi-layer foil sandwich is immersed in liquid and energized. Material inside electrode solidifies. Separately controllable voltage and current provides for programmable density, hardness, etc.

34 Other RP Systems (cont.) Masking & Depositing - Carnegie Mellon robotic control of metal spraying through a disposable, laser cut, mask. A complementary mask is used to spray low melting point support alloy. Shape Melting - Babcock & Wilcox controlled placement of gas metal arc welding wire weld deposit. Very closely controlled and monitored thermal conditions with localized cooling allow for control over material properties. Innumerable Variations

35 R & D in Rapid Prototyping Part Accuracy Improvement mathematical use of CSG and ray tracing vs.stl improved facet approximations process related z step resolution layer registration material related material selection/development stress relief, alternate build techniques to reduce deformation additional processing (eg. shot peening)

36 R & D in Rapid Prototyping (cont.) Materials improvements to current materials current materials weak and fragile development of low-shrink, less brittle plastics introduction of glass, carbon or graphite fibre mixtures including ceramics are being tested focus on end-use material requirement develop techniques to build with metal low melting point, binary metal powders deposition of droplets of molten metal from a moving nozzle breakthrough RP design based on materials knowledge

37 R & D in Rapid Prototyping (cont.) Systems improvements to current technologies incremental improvements to specific RP technologies generic improvements, applicable to several RP types development of new RP technology development of implementation knowledge desktop manufacturing, automated fabrication, tool-less manufacturing, free form fabrication workplace implications application identification and development virtual manufacturing, communications the personal factory

38 Examples of RP in Research Molecular Modeling Protein Kinase Molecular Docking Sites Earth Science Bathymetry Fault modeling Terrain surfaces Hurricane / meteorological modeling Ozone Hole over Antarctica

39 Examples of RP in Research Mechanical Medical Specific component models Clearance, fit, function verification Design process development Creation of mold blanks Customized devices for specific patients Mathematical Surface Visualization

40 Introduction to Rapid Tooling Def n : A process by which RP technology is used to allow manufacturers to speed up the prototype tooling process without committing to costly and time consuming hard tooling.

41 Rapid Tooling Evolved dramatically in 1996 RT allows user to build a tool that can produce 100s, 1000s, or even s of parts quickly and at a lower cost.

42 The Evolution of RT Rapid Soft Tooling (RST) Rapid Bridge Tooling (RBT) Rapid Hard Tooling (RHT)

43 The Evolution of RT

44 Rapid Soft Tooling (RST) Tools are made using RP Parts are molded using Room Temperature Vulcanization (RTV) Vacuum Casting NOT Injection Molded NOT fabricated from end use material Typically less than 30 parts per mold

45 Rapid Bridge Tooling (RBT) Utilizes advanced RP techniques Accurate Clear Epoxy Resins (ACER) Injection molded parts Use of ACES allows entire project from CAD design to 100 molded prototypes in 5 days.

46 Rapid Hard Tooling (RHT) Fabricate the RP part Cover part with flexible silicon rubber Break apart and send to local foundry Ceramic part replica of RP part Aluminum tooling cast from ceramic part Parts can be shot in real production material

47 ENGI 7962 Computer-Aided Engineering