Kumar / Pandey / Wimpenny 3D Printing and Additive Manufacturing Technologies

1. Auflage 2018
ISBN: 978-981-13-0305-0
Verlag: Springer Nature Singapore
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 308 Seiten

Reihe: Engineering

This book presents a selection of papers on advanced technologies for 3D printing and additive manufacturing, and demonstrates how these technologies have changed the face of direct, digital technologies for the rapid production of models, prototypes and patterns. Because of their wide range of applications, 3D printing and additive manufacturing technologies have sparked a powerful new industrial revolution in the field of manufacturing. The evolution of 3D printing and additive manufacturing technologies has changed design, engineering and manufacturing processes across such diverse industries as consumer products, aerospace, medical devices and automotive engineering. This book will help designers, R&D personnel, and practicing engineers grasp the latest developments in the field of 3D Printing and Additive Manufacturing.  

Mr. Jyothish Kumar is the Founder CEO of Rapitech Solutions Inc., Bangalore and the Founder President of the Additive Manufacturing Society of India (AMSI), Bangalore. He received his Bachelor of Engineering in Mechanical Engineering from the National Institute of Engineering, Mysore and his Master's degree in Rapid Product Development from De Montfort University, UK. Mr. Kumar is currently pursuing PhD research in Aerospace Applications of Additive Manufacturing Technologies. Prior to that he served in various areas of the Mechanical Engineering industry, such as Quality Assurance, Marketing, Sales and Product Development in India and abroad. He has specialized experience in Quality Management Systems and Rapid Product Development. Mr. Kumar is currently the Managing Editor of the Additive Manufacturing Technology Magazine, the only journal for in 3D Printing and Additive Manufacturing Technologies in India.  Professor Pulak M. Pandey is currently serving as a Professor in the Department of Mechanical Engineering in Indian Institute of Technology (IIT) Delhi. After completing his B.Tech from H.B.T.I. Kanpur in 1993, he went on to do his Master's and PhD from IIT Kanpur, where his PhD was in the area of Additive Manufacturing/3D Printing. In IIT Delhi, Dr Pandey diversified his research areas in the field of micro and nano finishing, micro-deposition and also continued working in the area of 3D Printing. He supervised 21 Ph.D.s and more than 33 M.Tech. theses in last 10 years and also filed 13 Indian patent applications. He has approximately 119 international journal papers and 44 international/national refereed conference papers to his credit. These papers have been cited for more than 3056 times with h-index as 26. He received Highly Commended Paper Award by Rapid Prototyping Journal for the paper 'Fabrication of three dimensional open porous regular structure of PA 2200 for enhanced strength of scaffold using selective laser sintering' published in 2017. Many of the B. Tech and M. Tech projects he has supervised have received awards and accolades, and his students have won the GYTI (Gandhian Young Technological Innovation) Award in 2013, 2015 and 2017. Prof Pandey is the recipient of the Outstanding Young Faculty Fellowship (IIT Delhi) sponsored by Kusuma Trust, Gibraltar and J.M. Mahajan outstanding teacher award of IIT Delhi.    Professor David Ian Wimpenny is currently the Chief Technologist at the Manufacturing Technology Centre (MTC), Coventry, UK. He joined the MTC as a Technology Manager in 2011 and worked as a full time Technologist of the Component Technology Group at the MTC. He is the Chairman of the Additive Manufacturing & 3D Printing Forum for the HVM Catapult. His past roles include being Head of the research at De Montfort University, Leicester, UK from 2009 to 2011, and Director of the Additive Manufacturing Technology Group at the Department of Engineering and Technology, De Montfort University, from 2001 to 2011. Professor Wimpenny is also a member of the Additive Manufacturing Special Interest Group (AM-SIG), which was established by the Technology Strategy Board to develop a road map for the UK AM sector. His major activities are in the areas of Additive Manufacturing, Rapid Product Development, Laser Printing, Surface Engineering and Manufacturing Production Tooling. He has published more than 60 papers in international/national journals and presented papers at seminars and international conferences. He holds three patents for Rapid Prototyping, Reverse Engineering and Computer Aided Design. Professor Wimpenny also serves on the review committee of several reputed International Journals like Additive Manufacturing, Rapid Prototyping, Materials Processing Technology etc. He has two books to his credit, and was a co-editor of the Rapid Prototyping Case Book, Professional Engineering Publications. 

Autoren/Hrsg.

Kumar, L. Jyothish

Pandey, Pulak M.

Wimpenny, David Ian

Inhaltsverzeichnis

1;Preface;5
2;Acknowledgements;6
3;Contents;7
4;About the Editors;10
5;1 Finite Element Analysis of Melt Pool Characteristics in Selective Laser Spot Melting on a Powder Layer;12
5.1;Abstract;12
5.2;1 Introduction;13
5.3;2 Model Description;14
5.3.1;2.1 Powder Bed Properties;16
5.3.2;2.2 Governing Transport Equations;16
5.3.2.1;2.2.1 Phase Change in the Powder Layer;16
5.3.2.2;2.2.2 Substrate;18
5.3.3;2.3 Boundary Conditions;18
5.3.4;2.4 Volume Contraction of the Powder Layer;19
5.4;3 Results;20
5.5;4 Conclusion;23
5.6;References;23
6;2 Thermal Transport Phenomena in Multi-layer Deposition Using Arc Welding Process;25
6.1;Abstract;25
6.2;1 Introduction;26
6.3;2 Model Description;28
6.4;3 Governing Transport Equations;29
6.4.1;3.1 Mass Conservation;30
6.4.2;3.2 Energy Conservation;30
6.4.3;3.3 Momentum Conservation;30
6.4.4;3.4 Boundary Conditions;31
6.5;4 Results and Discussions;32
6.5.1;4.1 Temperature Distribution;32
6.5.2;4.2 Velocity Distribution and Melt Pool Shape;34
6.6;5 Conclusions;35
6.7;References;36
7;3 Comparison of Bonding Strength of Ti–6Al–4V Alloy Deposit and Substrate Processed by Laser Metal Deposition;38
7.1;Abstract;38
7.2;1 Introduction;38
7.3;2 Experimental Methods;39
7.3.1;2.1 Three-Point Bending Test of Ti–6Al–4V Deposit and Substrate;40
7.4;3 Results and Discussion;42
7.4.1;3.1 Three-Point Bending Test of Ti–6Al–4V Deposit and Substrate;42
7.4.2;3.2 Scanning Electron Micrograph (SEM) and Energy Dispersive X-ray Spectroscope Studies (EDS);44
7.5;4 Conclusion;45
7.6;Acknowledgements;46
7.7;References;46
8;4 Study on Rayleigh–Bénard Convection in Laser Melting Process;47
8.1;Abstract;47
8.2;1 Introduction;47
8.3;2 Numerical Model;48
8.4;3 Results and Discussions;50
8.5;4 Conclusion;52
8.6;References;52
9;5 Enhancing Surface Finish of Fused Deposition Modelling Parts;53
9.1;Abstract;53
9.2;1 Introduction;54
9.3;2 Literature Review;55
9.4;3 Experimental Method;56
9.4.1;3.1 Stage-I: Prototype Fabrication;57
9.4.2;3.2 Stage-II: Chemical Post Processing;58
9.5;4 Analysis of Surface Roughness Results;58
9.6;5 Chemical Post Processing;62
9.7;6 Conclusions;63
9.8;References;64
10;6 Development and Analysis of Accurate and Adaptive FDM Post-finishing Approach;66
10.1;Abstract;66
10.2;1 Introduction;67
10.3;2 A New Methodological Framework for Post-Finishing Operation;68
10.3.1;2.1 Selective Melting (SM) Tool;73
10.3.2;2.2 Thermally Assisted Finishing (TAF) and Surface Roughness Measurement;74
10.4;3 Results and Discussion;74
10.4.1;3.1 Surface Profiles Characterization Analysis;76
10.5;4 Conclusions;77
10.6;References;77
11;7 Toolpath Generation for Additive Manufacturing Using CNC Milling Machine;79
11.1;Abstract;79
11.2;1 Introduction;80
11.3;2 Methodology;81
11.3.1;2.1 CAD Model and STL Preparation;81
11.3.2;2.2 Importing STL in MATLAB;81
11.3.3;2.3 Slicing of the Tessellated Model;82
11.3.4;2.4 Raster/Perimeter Based Tool Path;82
11.4;3 Development of Graphical User Interface (GUI);84
11.5;4 Experimental Validation of Toolpath Through CNC Milling Machine;86
11.6;5 Conclusion;87
11.7;Acknowledgements;88
11.8;References;88
12;8 Modelling of Heat Transfer in Powder Bed Based Additive Manufacturing Process Using Lattice Boltzmann Method;89
12.1;Abstract;89
12.2;1 Introduction;90
12.3;2 Numerical Modelling;91
12.3.1;2.1 Computational Domain;95
12.4;3 Results and Discussion;96
12.5;4 Conclusions;99
12.6;References;99
13;9 Effect of Process Parameters on Mechanical Properties of Solidified PLA Parts Fabricated by 3D Printing Process;101
13.1;Abstract;101
13.2;1 Introduction;101
13.3;2 Planning of Experiments;103
13.4;3 Results and Discussions;105
13.4.1;3.1 Analysis for Tensile Strength;105
13.4.2;3.2 Analysis for Flexural Strength;107
13.5;4 Conclusions;109
13.6;References;109
14;10 Metal Powder Based Additive Manufacturing Technologies—Business Forecast;111
14.1;Abstract;111
14.2;1 Introduction;112
14.3;2 AM Challenges—Techno-economic Barriers;113
14.4;3 Metal Powder for AM;114
14.4.1;3.1 Metal AM Capabilities;115
14.5;4 AM Forecast;116
14.5.1;4.1 Revenue Estimates for 2016–25 Using CAGR;116
14.5.2;4.2 Multiple Regression;119
14.6;5 AM Patents;120
14.7;6 Conclusions;122
14.8;References;123
15;11 Design and Development of Drug Delivery System for Chronic Wound Using Additive Manufacturing;125
15.1;Abstract;125
15.2;1 Introduction;125
15.3;2 Literature Review;127
15.4;3 Design and Manufacture of the Product;127
15.4.1;3.1 Modelling;127
15.4.2;3.2 Manufacturing Method;128
15.4.3;3.3 Manufacture of the End Product;128
15.4.3.1;3.3.1 Preprocessing;130
15.4.3.2;3.3.2 Building;130
15.4.3.3;3.3.3 Post Process;130
15.5;4 Conclusion;131
15.6;References;131
16;12 Design and Development of Orthosis for Clubfoot Deformity;133
16.1;Abstract;133
16.2;1 Introduction;133
16.3;2 Literature Review;134
16.3.1;2.1 Congenital Malformations;135
16.3.2;2.2 Club Foot Treatment;137
16.4;3 Design of the Customized Orthosis for Clubfoot;138
16.4.1;3.1 Design I;138
16.4.2;3.2 Design-II;139
16.4.3;3.3 Design-III;140
16.5;4 Manufacturing of Customized Orthosis;141
16.5.1;4.1 Machine Specifications;141
16.5.2;4.2 Manufacturing of the Prototypes;141
16.6;5 Conclusion;143
16.7;References;144
17;13 Optimization of Selective Laser Sintering Process Parameters on Surface Quality;146
17.1;Abstract;146
17.2;1 Introduction;146
17.3;2 Experimental Methods and Methodology;148
17.3.1;2.1 Processing of Specimen;148
17.3.2;2.2 Selection of SLS Process Parameters and Their Levels;149
17.3.3;2.3 Taguchi Quality Engineering;149
17.3.4;2.4 Selection of Orthogonal Array (OA);150
17.3.5;2.5 Process Parameter and Responses;150
17.4;3 Results and Discussion;152
17.4.1;3.1 Taguchi Analysis of Length (L) on SLS Process;152
17.4.2;3.2 Taguchi Analysis of Depth (D) on SLS Process;155
17.4.3;3.3 Taguchi Analysis of Surface Roughness (Ra) on SLS Process;158
17.5;4 Conclusion;161
17.6;References;161
18;14 Reconstruction of Damaged Parts by Integration Reverse Engineering (RE) and Rapid Prototyping (RP);163
18.1;Abstract;163
18.2;1 Introduction;164
18.3;2 Experimental Process for Replacement of Damaged Parts;164
18.4;3 Reverse Engineering (RE);165
18.4.1;3.1 Contact Based Scanning Technique;166
18.4.2;3.2 Non-contact Based Scanning Technique;166
18.5;4 Formation of Modified Model;166
18.6;5 Rapid Prototyping (RP);166
18.7;6 Case Study—Gear Wheel;167
18.7.1;6.1 3D Scanning of Damaged Gear Wheel;168
18.7.2;6.2 Reconstruction of Broken and Damaged Area of Gear Wheel;169
18.7.3;6.3 Rapid Prototyping of New Created Parts;173
18.8;7 Conclusions;174
18.9;References;175
19;15 The Impact of Additive Manufacturing on Indian GDP;176
19.1;Abstract;176
19.2;1 Introduction;177
19.2.1;1.1 Additive Manufacturing;177
19.2.2;1.2 3D Printers;177
19.2.3;1.3 Types of 3D Printing Technology;178
19.2.3.1;1.3.1 Fused Deposition Modelling;178
19.2.3.2;1.3.2 Stereo-Lithography;179
19.2.3.3;1.3.3 Selective Laser Sintering;179
19.3;2 Contribution of Manufacturing To GDP;181
19.3.1;2.1 Indian Manufacturing GDP;181
19.3.2;2.2 Employment in Manufacturing Sector;182
19.4;3 Effects of Additive Manufacturing on India;183
19.4.1;3.1 Applications;183
19.5;4 Future Project Scope;187
19.6;5 Conclusions;187
19.7;Acknowledgements;188
19.8;References;188
20;16 Optimization of the Print Quality by Controlling the Process Parameters on 3D Printing Machine;189
20.1;Abstract;189
20.2;1 Introduction;189
20.3;2 Methodology;191
20.3.1;2.1 Work Material;191
20.3.2;2.2 Experimental Set Up;191
20.4;3 Model data;192
20.4.1;3.1 Process Parameters;192
20.5;4 Results and Discussion;193
20.6;5 Conclusion;196
20.7;References;196
21;17 A Review on Current State of Art of Bioprinting;197
21.1;Abstract;197
21.2;1 Introduction;197
21.3;2 3D Bioprinting Approaches;198
21.4;3 The Process;199
21.5;4 Bioprinting Techniques;200
21.6;5 Applications;202
21.7;6 Future Prospects;202
21.8;References;203
22;18 A Turnkey Manufacturing Solution for Customized Insoles Using Material Extrusion Process;204
22.1;Abstract;204
22.2;1 Introduction;205
22.3;2 Insole Personalization and Manufacturing Process;206
22.3.1;2.1 Foot Digitization Using Foot Measurement System;206
22.3.2;2.2 Foot Diagnosis;209
22.3.3;2.3 Insole Design Software;209
22.3.4;2.4 Additive Manufacturing of Insoles;211
22.4;3 Results and Evaluation Criteria;213
22.5;4 Conclusions;216
22.6;References;217
23;19 Parameter Optimization for Polyamide in Selective Laser Sintering Based on Mechanical Behavior;218
23.1;Abstract;218
23.2;1 Introduction;218
23.3;2 Experimentation;220
23.3.1;2.1 Preparation of Test Samples by Using SLS Process;220
23.3.2;2.2 Selection of Factors and Their Levels of SLS Process;221
23.3.3;2.3 Taguchi Design of Experiments;221
23.3.4;2.4 Assigned Orthogonal Array;222
23.3.5;2.5 Design of Experiments with Results;223
23.4;3 Results and Discussion;224
23.4.1;3.1 Taguchi Analysis of Hardness (H) on SLS Process;224
23.4.2;3.2 Taguchi Analysis of Ultimate Tensile Strength (UTS) on SLS Process;225
23.5;4 Conclusion;231
23.6;References;231
24;20 Analysis of Adjacent Vertebrae Post Vertebroplasty;233
24.1;Abstract;233
24.2;1 Introduction;234
24.3;2 Methodology;234
24.3.1;2.1 3D Modelling of Normal Vertebrae Using Mimics;235
24.3.2;2.2 Meshing in 3-Matic;235
24.3.3;2.3 Stress Analysis of Normal Vertebrae Using ANSYS;236
24.3.4;2.4 3D Modelling of Fractured Vertebrae Using Mimics;236
24.3.5;2.5 Stress Analysis of Fractured Vertebrae Using ANSYS;236
24.3.6;2.6 3D Modelling of Cement Injected Vertebrae Using Mimics;237
24.3.7;2.7 Stress Analysis of Cement Injected Vertebrae Using ANSYS;238
24.4;3 Results and Discussions;238
24.5;4 Conclusion;242
24.6;References;242
25;21 Design and Processing of Functionally Graded Material: Review and Current Status of Research;243
25.1;Abstract;243
25.2;1 Introduction;244
25.3;2 Functionally Graded Materials;246
25.3.1;2.1 On the Basis of Amount of Volume in Which Graded Properties Are Present;246
25.3.2;2.2 On the Basis of Nature of Gradient;246
25.3.3;2.3 Achievement of Graded Structures;246
25.4;3 Overview of Techniques Utilized for FGM Fabrication;247
25.5;4 Additive Manufacturing;248
25.6;5 Development of FGMs via Additive Manufacturing;249
25.7;6 Applications of FGMs;250
25.8;7 Future Trends;251
25.9;8 Concluding Summary;251
25.10;References;252
26;22 Development of Electrical Discharge Machining (EDM) Electrode Using Fused Deposition Modeling (FDM);256
26.1;Abstract;256
26.2;1 Introduction;257
26.3;2 Methodologies;257
26.3.1;2.1 Electrode Preparation;257
26.3.2;2.2 Experimental Set-up;258
26.3.3;2.3 Design of Experiments;258
26.3.4;2.4 Data Collection;259
26.3.5;2.5 Calculation of Responses;259
26.4;3 Result and Discussion;261
26.5;4 Analysis;262
26.5.1;4.1 Mathematical Analysis;262
26.5.1.1;4.1.1 Regression Analysis;262
26.5.1.2;4.1.2 Analysis of Variance (ANOVA);263
26.5.2;4.2 Comparison Between Experimental and Mathematical Analysis;264
26.5.2.1;4.2.1 RP Electrode;264
26.5.2.2;4.2.2 Solid Electrode;265
26.6;5 Conclusions;266
26.7;Acknowledgements;267
26.8;References;267
27;23 State of the Art of Powder Bed Fusion Additive Manufacturing: A Review;268
27.1;Abstract;268
27.2;1 Introduction;269
27.3;2 Powder Bed Fusion Additive Manufacturing (PBF);270
27.4;3 Some Recent Studies Related to Powder Bed Fusion Additive Manufacturing;272
27.5;4 Concluding Remarks;277
27.6;References;277
28;24 Distortion in Metal Additive Manufactured Parts;279
28.1;Abstract;279
28.2;1 Introduction;279
28.3;2 Defects in Metal Additive Manufacturing Process;281
28.3.1;2.1 Defects Due to Geometry of the Part, Orientation and Supports;281
28.3.2;2.2 Defects Due to Improper Process Control;283
28.3.3;2.3 Defects Based on the Materials Used;285
28.3.4;2.4 Defects Due to Physical Phenomenon;287
28.4;3 Distortion Characterisation;288
28.5;4 Conclusion;289
28.6;References;289
29;25 Laser Metal Deposition of Titanium Parts with Increased Productivity;294
29.1;Abstract;294
29.2;1 Introduction;294
29.3;2 System Setup and Methodology;295
29.4;3 Design;298
29.5;4 Part-Adaptive Process Planning;299
29.5.1;4.1 Manufacturing Tool Path Optimization;300
29.5.2;4.2 Part-Building Strategies;300
29.6;5 Geometrical Characterization;303
29.7;6 Metallographic Characterization (Porosity);305
29.8;7 Conclusions;307
29.9;References;308