Papers by Keyword: Rapid Manufacture (RM)

Abstract: Selective laser sintering technology is used for manufacturing parts from 316 stainless steel powders. Experiments were carried out on a Nd:YAG laser machine (LMY400) with 400W. Powder is layered by a roller over the surface of a 100mm diameter build cylinder. Effects of processing parameter on the scan line width, the scan line height, the single layer structure and the multilayer structure are investigated. The results show laser power, scan speed and layer thickness have a great effect on the scan line width and line height. Furthermore, the stable and continuous vectors are formed with the increasing of the number of layers.

Abstract: This paper describes a novel rapid manufacturing and remanufacturing system based on robotic gas metal arc welding. If worn parts are maintainable, this system play a repairer role; if worn parts are unfit to remain in service, this system play a manufacturer role. This system works in ‘modeling - slicing - stacking’ principle. First, Detecting and building three-dimensional models of damaged zone by structured light. Second, Slicing established three-dimensional model in layers with some thickness. Third, planning robotic tool path to get optimumwelding path and parameters. Finally, executing remanufacturing task with robotic GMAW stacking layer by layer. This system remanufactures parts in human - robot interactive way. Take a half cylinder shell as worn part, experiments are conducted. Results show the mean error of surface smoothness is less than 0.5mm.

Abstract: Additive processes can be defined as layered manufacturing, based on the dispersed/accumulated principle, Layered manufacturing is directly transforming 3D CAD models to real objects, the reverse engineering of mechanism can be applied to layered manufacturing for production complex geometries for long-term consistency, and the analysis demonstrates the application of the reverse engineering fulfills the segments of design, production, inspection, test. The most notable advantage is the combination of digital technology and geometric model rebuilding technology.

Abstract: Functionally graded mold (FGM) is the trend in the development of modern mold. Based on the optimization of electroforming and arc spray forming, a functionally graded mold with the structure of Ni-NiAl-ZnAl-Zn was manufactured, and the microstructure of the mold shell was analyzed. The experiments show that the manufacturing of functionally graded mold by electroforming and arc spray forming is feasible in engineering. The research is of significant value in exploring new manufacturing technology of functionally graded mold.

Abstract: Based on the review of current status and development of casting CNC manufacturing technology, this paper analyzes the characteristics and studies the mechanism of casting CNC cutting, along with the processing technique. A new casting CNC forming equipment is developed and successfully applied to the product development in automobile industry, mechanical industry and so on, which is regarded as a typical application case. Research indicates that patternless casting CNC manufacturing is a technical renovation compared to the traditional casting manufacturing, with traits of green, digital, flexibility, precision, rapidity. It’s applicable to the rapid manufacturing of metal casting either in single piece or small lot, and the pattern is unneeded. This new technology brings a promising application future in the automobile and mechanical equipment industries.

Abstract: As several of the free form fabrication processes progress with continuous process and material improvements, the feasibility of Rapid Manufacturing becomes more and more of a reality. Defined as the use of a Computer Aided Design (CAD) based automated additive manufacturing process to construct parts that are used directly as finished products and components, some of the rapid manufacturing processes are already competing with traditional processes such as injection moulding and progress is being made in applying the new technologies to the processing of metals, envisioning additive manufacture of high strength parts of unlimited complexity. While there have been quite a few successful attempts in the rapid production of complex medical implants using titanium alloys, 3D printing of sand moulds opens up yet another rapid manufacturing front, allowing for the rapid casting of aluminium and magnesium alloys. The effectiveness of such processes is yet to be researched in terms of process and product characteristics and the overall economy. This paper attempts to review some of the promising rapid manufacturing technologies for light metals processing and presents results of experimental investigations conducted to evaluate the effectiveness of the rapid casting process currently researched at the Rapid Product Development Centre of AUT University.

Abstract: Based on the annual sales volume, stereolitography (SLA) can be considered a Rapid Prototyping (RP) technology with a promising future. Besides being the pioneering equipment, when RP took the first steps in 1988, this technology has been developed with interesting and fast innovations, and a great activity in patents registration. One can assist to a strong research seeking the enlargement of the system capacity to produce large and micro-size parts, and simultaneously impose the technology as a mass production process that is evolving towards a true Rapid Manufacturing (RM) technology. SLA is an excellent tool to materialize concepts and ideas due to the high-resolution capacity, transparency and fine details of the models and prototypes that can be produced. In this study, the state of art of SLA is analyzed and the recent innovations are presented, and considering that the authors have a considerable experience in supervising design students, from different universities, some of the more emblematic projects that were developed at INEGI – Institute of Mechanical Engineering and Industrial Management, are presented. SLA and direct conversion processes were combined to produce new products in materials such as glass, ceramics and metals, for different industrial sectors.

Abstract: For a comprehensive understanding of the direct metal laser sintering (DMLS) process and for the successful introduction of this technology, some investigations related to the characteristics of the powders and the individual sintered layers were therefore performed. Also possibilities of hard coatings deposition for further improvements the wear and temperature resistance of tool inserts, and investigations particularly focused into the industrial applications of DMLS tooling inserts are presented.

Abstract: Direct Metal Laser Sintering (DMLS) has been utilized for prototype manufacturing of functional metal components for years now. During this period the surface quality, mechanical properties, detail resolution and easiness of the process have been improved to the level suitable for direct production of complex metallic components for various applications. The paper will present the latest DMLS technology utilizing EOSINT M270 laser sintering machine and EOSTYLE support generation software for direct and rapid production of complex shaped metallic components for various purposes. The focus of the presentation will be in rapid manufacturing of customized biomedical implants and surgical devices of the latest stainless steel, titanium and cobalt-chromium-molybdenum alloys. In addition to biomedical applications, other application areas where complex metallic parts with stringent requirements are being needed will be presented.

Abstract: The microstructure and properties of tool steel parts built by laser powder deposition (LPD) depend considerably on the build-up strategy and on the processing parameters used. This dependence can lead to inconsistent results which may limit the widespread acceptance of LPD. There is, thus, a need for efficient process optimisation tools that take into consideration the complex phase transformations that may occur during the part build-up process and their effect on final properties. A model coupling finite element heat transfer calculations with transformation kinetic theory has been developed, which allows the microstructure and property distributions in parts produced by LPD to be predicted. Application of this model to the deposition of tool steels not only explains the origin of the heterogeneous distribution of properties usually mentioned in the literature but also allows designing build-up strategies that consistently lead to homogeneous, high quality parts. Its application to the study of the influence of substrate pre-heating and idle time between the deposition of consecutive layers is illustrated in the present paper.