Gupta Near Net Shape Manufacturing Processes

1. Auflage 2019
ISBN: 978-3-030-10579-2
Verlag: Springer International Publishing
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 193 Seiten

Reihe: Materials Forming, Machining and Tribology

This book covers the mechanism, salient features, and important aspects of various subtractive, additive, forming and hybrid techniques to manufacture near net-shaped products. The latest research in this area as well as possible future research are also highlighted.

Dr. Kapil Gupta is a Senior Lecturer at the Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, South Africa. Advanced machining processes, sustainable manufacturing, precision engineering and gear technology are his areas of interest and specialization. Currently, he is performing research in advanced/modern machining, sustainable manufacturing and gear engineering.

Autoren/Hrsg.

Gupta, Kapil

Inhaltsverzeichnis

1;Preface;6
2;Contents;8
3;1 Towards the Manufacturing of Near Net Shape Medical Prostheses in Polymeric Sheet by Incremental Sheet Forming;9
3.1;Abstract;9
3.2;1 Introduction;10
3.3;2 Process Parameters Analysis on Polymer Basic Geometries Manufactured by SPIF and Recommendations;13
3.3.1;2.1 Influence on Forming Force;16
3.3.2;2.2 Influence on Forming Cost;18
3.3.3;2.3 Influence on Temperature;20
3.3.4;2.4 Influence on Formability;22
3.3.4.1;2.4.1 Scientific Context;23
3.3.4.2;2.4.2 Experimental Methodology for Evaluation Formability;23
3.3.4.3;2.4.3 Experimentation;24
3.4;3 Cases of Study: Approaching ISF to the Manufacturing of Custom Cranial Implants;29
3.4.1;3.1 Case Study 1. Preliminary Tests to Show the Potential of the Technology;30
3.4.2;3.2 Case Study 2. Customized Cranial Implant Manufactured with UHMWPE;31
3.4.2.1;3.2.1 Geometric Accuracy;32
3.4.2.2;3.2.2 Cost;34
3.5;4 Guidelines and Discussion;35
3.5.1;4.1 Guidelines;35
3.5.2;4.2 Summary;37
3.6;References;39
4;2 Developments in Friction Stir Processing—A Near Net Shape Forming Technique;42
4.1;Abstract;42
4.2;1 Introduction;43
4.3;2 FSP Variables for Superplastic Forming;45
4.3.1;2.1 Tool Rotation and Travel Speed;45
4.3.2;2.2 Tool Geometry;48
4.3.3;2.3 Multiple Passes;50
4.4;3 Superplastic Forming;52
4.4.1;3.1 Microstructure Requirement;52
4.4.2;3.2 Superplastic Forming Properties;53
4.4.2.1;3.2.1 High Strain Rate Superplastic Forming (HSRSF);53
4.4.2.2;3.2.2 Low-Temperature Superplastic Forming;54
4.4.3;3.3 Superplastic Forming in Aluminum Alloys by Friction Stir Processed;54
4.5;4 Friction Stir Casting to Modify/Repair Cast Properties;56
4.6;References;57
5;3 Evolution in Additive Manufacturing Techniques of Metals as Net-Shaped Products;61
5.1;Abstract;61
5.2;1 Introduction;62
5.3;2 Components and Functioning of Various Additive Manufacturing Process;63
5.3.1;2.1 Laser Additive Manufacturing;63
5.3.1.1;2.1.1 High Power Laser;64
5.3.1.2;2.1.2 Feeding System;65
5.3.1.2.1;Wire Feeding System;65
5.3.1.2.2;Powder Feeding System;66
5.3.1.3;2.1.3 CNC Workstation;67
5.3.2;2.2 MIG Based Additive Manufacturing;68
5.3.2.1;2.2.1 Influence of Wire Arc Additive Manufacturing Parameters;68
5.3.2.2;2.2.2 Influence of Ambient Temperature;68
5.3.2.3;2.2.3 Influence of Surface Active Elements;70
5.3.3;2.3 Cold Spray Deposition Process;71
5.3.3.1;2.3.1 Influence of Powder Particle;71
5.3.3.2;2.3.2 Influence of Gas Flow;71
5.3.3.3;2.3.3 Influence of Powder Particle Speed;72
5.4;3 Experimental Procedure;72
5.4.1;3.1 Laser Additive Manufacturing;72
5.4.2;3.2 MIG Based Additive Manufacturing;74
5.4.3;3.3 Cold Spray Deposition;76
5.5;4 Analyses of the Samples and Discussion;77
5.5.1;4.1 Scanning Electron Microscopy (SEM);77
5.5.2;4.2 Microstructure;78
5.5.3;4.3 Microhardness Properties;79
5.6;5 Conclusion;80
5.7;Acknowledgements;81
5.8;References;81
6;4 Near Net Shape Manufacturing of Dental Implants Using Additive Processes;84
6.1;Abstract;84
6.2;1 Introduction;85
6.3;2 Structure and Properties of Teeth;86
6.4;3 Requirements and Materials for Dental Implants;88
6.5;4 Materials for Dental Implants;90
6.5.1;4.1 Titanium and Titanium Alloys;90
6.5.2;4.2 Zirconia Ceramics;90
6.6;5 Additive Manufacturing;91
6.6.1;5.1 Binder Jetting;92
6.6.2;5.2 Material Extrusion;94
6.6.3;5.3 Powder Bed Fusion;95
6.6.4;5.4 Vat Photo-Polymerization;100
6.6.5;5.5 Sheet Lamination (SL) and Direct Energy Deposition;101
6.7;6 Clinical Evaluation of 3D Implants;102
6.8;7 Conclusion and Future Outlook;104
6.9;References;105
7;5 Laser Additive Manufacturing Processes for Near Net Shape Components;110
7.1;Abstract;110
7.2;1 Introduction;110
7.3;2 Manufacturing of Macroscale Components;112
7.3.1;2.1 Stereolithography (SLA);112
7.3.1.1;2.1.1 Materials. Resins for Stereolithography;114
7.3.1.2;2.1.2 Laser-Induced Curing During Stereolithography;115
7.3.2;2.2 Powder Bed Techniques: Selective Laser Sintering (SLS) and Selective Laser Melting (SLM);117
7.3.2.1;2.2.1 Binding of Particles in Selective Laser Sintering;118
7.3.2.2;2.2.2 Processing Parameters;118
7.3.2.3;2.2.3 Materials;119
7.3.3;2.3 Additive Manufacturing Based on Laser Cladding;121
7.3.3.1;2.3.1 Laser Processing Parameters;122
7.3.3.2;2.3.2 Powder Feeding and Interactions;123
7.3.3.3;2.3.3 Transport Properties;124
7.3.3.4;2.3.4 Materials;125
7.3.4;2.4 Laminated Object Manufacturing (LOM);126
7.3.4.1;2.4.1 Processing Parameters in Laminated Object Manufacturing;127
7.3.4.2;2.4.2 Materials;127
7.4;3 Manufacturing of Microscale Components;128
7.4.1;3.1 Two-Photon Polymerization (2PP);128
7.4.2;3.2 Laser Microcladding;130
7.5;4 Challenges, Future Prospects and Conclusions;132
7.6;Acknowledgements;134
7.7;References;134
8;6 Near Net Shape Manufacturing of Miniature Spur Brass Gears by Abrasive Water Jet Machining;147
8.1;Abstract;147
8.2;1 Introduction;148
8.3;2 Experimentation;150
8.4;3 Results and Discussion;153
8.4.1;3.1 Empirical Modeling;154
8.4.2;3.2 Influence of AWJM Parameters on Surface Quality of Gears;155
8.4.2.1;3.2.1 Effect of Water Jet Pressure;156
8.4.2.2;3.2.2 Effect of Abrasive Mass Flow Rate;157
8.4.2.3;3.2.3 Effect of Stand-off Distance;157
8.5;4 Surface Quality Optimization;158
8.5.1;4.1 Confirmation Experiments;159
8.6;5 Conclusion;160
8.7;Acknowledgments;161
8.8;References;161
9;7 Fracture Forming Limits for Near Net Shape Forming of Sheet Metals;163
9.1;Abstract;163
9.2;1 Introduction;163
9.3;2 Failure by Fracture;164
9.3.1;2.1 Mode I—Tensile Fracture;165
9.3.2;2.2 Mode II—In-Plane Shear Fracture;168
9.4;3 Experimental Methodology;170
9.4.1;3.1 Mechanical Characterization of the Material;170
9.4.2;3.2 Formability Limits by Necking and Fracture Determination;171
9.4.3;3.3 Plan of Experiments;172
9.5;4 Results and Discussion;174
9.6;5 Conclusions;177
9.7;Acknowledgements;177
9.8;References;178
10;8 Advances in Near Net Shape Polymer Manufacturing Through Microcellular Injection Moulding;180
10.1;Abstract;180
10.2;1 Introduction;180
10.3;2 Theory Behind the Technology;181
10.3.1;2.1 Conventional and Microcellular Injection Moulding;181
10.3.2;2.2 Main Steps with the Technology;183
10.3.2.1;2.2.1 Super Critical Fluid Mixing and Dissolution;184
10.3.2.2;2.2.2 Cell Nucleation and Growth;184
10.3.2.3;2.2.3 Shaping Within the Mould;185
10.3.3;2.3 Cell Structure;185
10.3.4;2.4 Major Limitation of Microcellular Injection Moulding;186
10.4;3 Enhanced Microcellular Injection Moulding Manufacturing Techniques;186
10.4.1;3.1 Co-injection Moulding;186
10.4.2;3.2 Core-Back Processing;186
10.4.3;3.3 Gas Counter Pressure;187
10.4.4;3.4 Vario-thermal Moulding;187
10.4.5;3.5 Mould Temperature Insulation Coatings;188
10.5;4 Conclusion;189
10.6;References;190
11;Index;193