PDPM Indian Institute of Information Technology, Design & Manufacturing, Jabalpur. (An Institute of ational Importance! "#$%$'
A) *+P*T Ad-anced Manufacturing Processes abII (M+%/!. +0periment o. "1 Modelling and 2reating 2omponent by using *P Machine.
3ubmitted by1
3ubmitted to1
Aayushi
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Dr. 4. 2helladurai,
Animesh 6umar Amar
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Assistant Professor,
An7it 6umar
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Perumalla 3ateesh 6umar $%$#55/ Prashant Meshram
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*an8eet 3ingh 6aura-
$%$#559
3hashan7 6umar
$%$#55:
3uhas 3 Arali7atti
$%$#5/#
;ada;ada- agesh 6umar
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IIITDMJabalpur
b8ecti-e • • •
Modeling a 3D solid model by using a CAD Software. Convert this solid model into STL format. Using fused deposition modeling mahine reate a omponent by !apid "rototyping tehni#ue.
Introduction "rototyping or model ma$ing is one of the important steps to finali%e a produt design. !apid "rototyping &!"' by layer(by(layer material deposition started during early )*+,s with the enormous growth in Computer Aided Design and Manufaturing &CAD-CAM' tehnologies. !apid prototyping tehnology aids this proess. !apid prototyping automates the ma$ing of a prototype. t builds a prototype part from a three(dimensional &3(D' CAD drawing. /ther terms used for rapid prototyping0 Des$top manufaturing1 Automated fabriation1 Tool(less manufaturing1 2ree(form fabriation and 3D printing. !" models an be used to reate male models for tooling1 suh as silione rubber molds and investment asts. n some ases1 the !" part an be the final part1 but typially the !" material is not strong or aurate enough. hen the !" material is suitable1 highly onvoluted shapes &inluding parts nested within parts' an be produed beause of the nature of !".
To inrease effetive ommuniation.
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To derease development time.
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To derease ostly mista$es.
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To minimi%e sustaining engineering hanges.
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To e4tend produt lifetime by adding neessary features and eliminating redundant features early in the design.
)asic Principle of *apid Prototyping Process !" proess belong to the generative &or additive' prodution proesses unli$e subtrative or forming proesses suh as lathing1 milling1 grinding or oining et. in whih form is shaped by material removal or plasti deformation. n all ommerial !" proesses1 the p art is fabriated by deposition of layers ontoured in a &4(y' plane two dimensionally. The third dimension &%' results from single layers being sta$ed up on top of eah other1 but not as a ontinuous %(oordinate. Therefore1 the prototypes are very e4at on the 4(y plane but have stair(stepping effet in %( diretion. f model is deposited with very fine layers1 i.e.1 smaller %(stepping1 model loo$s li$e original. !" an be lassified into two fundamental proess steps namely generation of mathematial layer information and5 generation of physial layer model.
3teps of *apid Prototyping Typial proess hain of various !" systems has following steps and is shown in 2igure ). ). Creation of 6eometri Model 5. Tessellation 3. Determination of optimum orientation 7. Sliing 8. Support generation 9. Tool path generation :. "art 2abriation +. "ost "roessing
2igure )0 !" proess hain showing fundamental proess steps
>used Deposition Modelling /b;ets reated with an 2DM printer start out as omputer(aided design &CAD' files. s being printed. During printing1 these materials ta$e the form of plasti threads1 or filaments1 whih are unwound from a oil and fed through an e4trusion no%%le. The no%%le melts the filaments and e4trudes them onto a base1 sometimes alled a build platform or table.
n a typial 2DM system1 the e4trusion no%%le moves over the build platform hori%ontally and vertially1 BdrawingB a ross setion of an ob;et onto the platform. This thin layer of plasti ools and hardens1 immediately binding to the layer beneath it. /ne a layer is ompleted1 the base is lowered = usually by about one(si4teenth of an inh = to ma$e room for the ne4t layer of plasti. "rinting time depends on the si%e of the ob;et being manufatured. Small ob;ets = ;ust a few ubi inhes = and tall1 thin ob;ets print #ui$ly1 while larger1 more geometrially omple4 ob;ets ta$e longer to print. Compared to other 3D printing methods1 suh as stereolithography &SLA' or seletive laser sintering &SLS'1 2DM is a fairly slow proess. /ne an ob;et omes off the 2DM printer1 its support materials are removed either by soa$ing the ob;et in a water and detergent solution or1 in the ase of thermoplasti supports1 snapping the support material off by hand. /b;ets may also be sanded1 milled1 painted or plated to improve their funtion and appearane.
2igure 50 Shemati model and wor$ing priniple of 2used Deposition Modeling "roess
Machine and Its 3pecifications n the TDM abalpur1 2DM 7,,m is available. The speifiations details of the mahine is given below0
2igure 30 2DM 7,,m
A. 3ystem 3pecifications
Table ) nvelope Si%e
)7 4 ), 4 ), in 388 4 587 4 587 mm Upgradeable to )9 4 )7 4 )9 in 7,9 4 388 4 7,9 mm
Model Materials
A
Available Tips
2or ALL materials0 T)5-.,,:G &.):+ mm' E
&Slie Feights'
T)9-.,),G &.587 mm' plus 2or A
Support Strutures
ater soluble release supports for A
Auray
Models are produed within an auray of H,.,,8 inh &H.)5: mm' up to 8 inhes &)5: mm'. Auray on models greater than 8 inhes &)5: mm' is H,.,,)8 inh per inh &H,.,3+) mm'
Compatibility
indows IT 7.,1 indows 5,,,1 indows ?"
Ietwor$ Communiation
),-),, base T onnetion. thernet protool.
"ower !e#uirements
53, JAC 8,-9, F%1 3 phase1 )9A-phase &5,A dediated iruit re#uired'.
Si%e
2DM 7,,m0 8,.58 in. &)5:: mm' wide 4 38.58 in. &+*9 mm' deep 4 ::.58 in. &5)*: mm' high
eight
)9,, pounds &:59 $g' shipping weight
nvironmental
Ma4imum nvironmental Temperature0
!e#uirements
+8K2 &5*KC' Ma4imum Dew "oint0 :+K2 &58KC'
Clearane !e#uirements
2DM 7,,m0 Minimum vertial learane0 5+ inhes &:).)5 m'. Minimum side learane0 3, inhes &:9.5* m' &re#uired on eah side' Minimum front learane0 39 inhes &*).77 m'. Minimum ba$ learane0 )5 inhes &3,.7+ m'.
). i?uefier Tip 3pecifications
6eneral nformation
). The head assembly uses a support li#uefier tip and a model li#uefier tip. 5. There are 7 tip si%es available ( T),1 T)51 T)91 E T5, 3. 2or soluble support material0 2or 2DM 7,,m0 Use the T)5 S! tip for support when using modelling tips T),1 T)51 T)91 E T5,. Tip Compatibility and Seletion 2or 2DM 7,,m Table 5 shows the available material and tips. Table 50 2DM 7,,m Available Tips
2. Material )uild Temperatures
Table 3 shows the material build temperature values for the different materials
Deposition
Support
Letter ‘7’
2igure07 Solid Model of a Cube
Ad-antage Almost any shape or geometri feature an be produed. !edution in time and ost &ould range 8, *,N. ohler' rrors and flaws an be deteted at an early stage. !"-!M an be used in different industries and fields of life &mediine1 art and arhiteture1 mar$eting.' Disussions with the ustomer an start at an ear ly stage. Assemblies an be made diretly in one go. Material waste is redued. Io tooling is neessary. The designers and the mahinery an be in separate plaes.
Disad-antage The prie of mahinery and materials. The surfae is usually rougher than mahined surfaes. Some materials are brittle. The strength of !"(parts are wea$er in %(diretion than in other.
Application •
duation
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Aurately evaluate the patientOs anatomy "re(Surgial "lanning "re(Surgial !ehearsal !edue surgery time Try out different surgial approahes Surgial Training Tissue ngineering Die ma$ing of diesel engine.