Andreas Gebhardt. Rapid Prototyping HANSER. Hanser Publishers, Munich Hanser Gardner Publications, Inc., Cincinnati

Transcription

1 Andreas Gebhardt Rapid Prototyping HANSER Hanser Publishers, Munich Hanser Gardner Publications, Inc., Cincinnati

2 Contents 1 Product Development - Product Formation - Rapid Product Development New Demands - New Processes Changing Conditions for Product Development - Critical Factors Affecting Success Consequences for Product Development Critical Factors for Success and Competitive Strategies The Key Factor of Time Simultaneous Engineering - Concurrent Engineering Classical Steps of Product Development Requirements for New Product-Development Strategies The Principle of Simultaneous Engineering Models Model Classes Influence of Models to Speed Up Product Development Model Making by Rapid Prototyping as an Element of Simultaneous Engineering Rapid Prototyping Models as Guarantors of a Defined Database Definition: Rapid Prototyping - Rapid Tooling - Rapid Manufacturing Relating Rapid Prototyping Models to Product Development Phases 27 2 Characteristics of Generative Manufacturing Processes Basic Principles of Rapid Prototyping Processes Generation of Layer Information Description of the Geometry by a 3D Data Record Data Flow Modeling 3D Bodies in a Computer by Means of 3D CAD Generation of Geometrical Layer Information on Single Layers Projection of Geometrical Layer Information on the Layer Generation of the Physical Layer Model Solidification of Liquid Materials Photopolymerization - Stereolithography (SL) Generation from the Solid Phase Melting and Solidification of Powders and Granules - Laser Sintering (LS) Cutting from Foils - Layer Laminate Manufacturing (LLM) Melting and Solidification Out of the Solid Phase - Fused Layer Modeling (FLM) 67

3 XII Contents Conglutination of Granules and Binders - 3 D Printing Solidification from the Gaseous Phase - Laser Chemical Vapor Deposition (LCVD) Other Processes Classification of Generative Production Processes Summarizing Evaluation of the Theoretical Potentials of Rapid Prototyping Processes 72 Industrial Rapid Prototyping Systems Rapid Prototyping Process Chain Data Technique Prototyper Photopolymerization - Stereolithography (SL) Machine Specific Basic Principles StereoLithography Apparatus (SLA) - 3D Systems STEREOS-EOS Stereolithography -Fockele & Schwarze (F&S) Solid Ground Curing - Cubital Micro-stereolithography -MicroTEC Stereolithography -EnvisionTechnologies lll Stereolithography - Poly Jet - Objet Laser Sintering Machine-Specific Basic Principles Selective Laser Sintering - 3D Systems / DTM Laser Sintering - EOS Selective Laser Melting -Fockele & Schwarze Laser Cusing, Concept Laser Layer Laminate Manufacturing (LLM)) Machine-Specific Basic Principles Laminated Object Manufacturing (LOM) - Cubic Technologies / Helisys Rapid Prototyping System - Kinergy Selective Adhesive and Hot Press Process (SAHP) - Kira JP Systems 5 - Schroff Development Corp Layer Milling Process (LMP) -Zimmermann Stratoconception - Charlyrobot Stratified Object Manufacturing (SOM) -ERATZ/MEC Extrusion Processes Fused Deposition Modeling (FDM) - Stratasys Multiphase Jet Solidification (MJS) - ITP D Plotter - Stratasys ModelMaker- Solidscape / Sanders Prototype, Inc Multijet Modeling (MJM) - 3D Systems Three-Dimensional Printing (3DP) Processes 178

4 Contents XIII Rapid Prototyping System-Z Corporation Rapid Tooling System-ExtrudeHone Direct Shell Production Casting (DSPC) - Soligen Laser Generation Laser Engineered Net Shaping (LENS) - Optomec Conventional Prototype Processes and Hybrid Processes Conventional Processes: High-Speed Cutting (HSC) Hybrid Processes: Controlled Metal Buildup (CMB) Comparison of Rapid Prototyping Processes and Conventional Processes Summarizing Evaluation of Rapid Prototyping Processes Model Accuracy Surfaces Benchmark Tests and User Parts Comparative Evaluation of Prototypers for Functional Prototypes by Comparing Build Chambers, Accuracy, and Build Times Categorization of Prototypers m Model Classes Development Targets Follow-Up Processes Target Material Plastic Target Material Metal Rapid Tooling Principal Ways to Metal Tools Metal Tools Based on Plastic Rapid Prototyping Models Precision Casting of Rapid Prototyping Master Models Castings from Stereolithography Models Direct Use of Stereolithography Indirect Use of Stereolithography Metal Tools Based on Plastic Rapid Prototyping Processes Metal Tools Based on Metal Rapid Prototyping Processes Multi-Component Metal Powder LASER Sintering Single-Component Metal Powder Laser Sintering Laser Generation Summary and Perspectives Applications Rapid Prototyping in Industrial Product Development Example: Pump Housing Example: Office Lamp Example: Integrated Lamp Socket Example: Model Digger Arm Example: LCD Projector 246

5 XIV Contents Example: Capillary Bottom for Flower Pots Example: Casing for a Coffeemaker Example: Intake Manifold of a Four-Cylinder Engine Rapid Tooling in Industrial Product Development Example: Turbocharger Casing Example: Two-Piece Electric Connector Example: Injection Mold Headlight Dipper Arm Example: Permanent Mold for Precision Casting Models Rapid Prototyping for the Evaluation of Calculating Methods Models to Be Used in Calculating Methods - General Example: Photoelastic Stress Analysis for a Cam Rod of a Truck Engine Example: Thermoelastic Stress Analysis for Verifying the Stability of a Car Wheel Rim Rapid Prototyping in Medicine Anatomic Facsimile Models Taylored Implants Characteristics of Medical Models Example: Anatomic Facsimilies for a Reconstructive Osteotomy Example: Covering of a Cranium Defect by Titanium Implant (Cranioplasty) Rapid Prototyping in Art, Archaeology and Architecture Model Making m Art and Design Example Art: Computer Sculpture, Georg Glückman Example Design: Bottle Opener Example Archaeology: Bust of Queen Teje Model Building in Architecture Example Architecture: German Pavilion at Expo ' Example Architecture: House building Project Economic Aspects Strategic Aspects Operative Aspects Establishing the Optimal Rapid Prototyping Process or Processes Establishing the Costs of Rapid Prototyping Processes Service Make or Buy? Future Rapid Prototyping Processes Selected Trends in Material Development Application: Precision Casting Application: Simulation of Series Materials Selected Trends of Process Development Laser Sintering of One-Component Materials Laser Sintering in a Powder Bed - Selective Laser Powder Remelting (SLPR) 298

6 Contents XV Process Principle Characteristics of Quality Examples of Applications Laser Generation Principle of Process Quality Characteristics Examples of Application 309 Appendix 315 Al Economic Model by Siegwart and Singer 315 A2 Properties and Technical Data of Rapid Prototyping Systems and -Materials 320 A3 Abbreviations 364 References, Bibliography 365 Index 371