Meghanath Technica Seminar Report.docx

TITILE OF TECHNICAL SEMINAR A Technical Seminar Report submitted in partial fulfillment of the requirements For the award of degree of

BACHELOR OF TECHNOLOGY In MECHANICAL ENGINEERING

By

K MEGHANATH (164G5A0310) Under the Esteemed Guidance of Mr L VAMSI KRISHNA REDDY

M.Tech (P.hd)

Assistant Professor Mechanical Engineering Dept.

Department of Mechanical Engineering SRINIVASA RAMANUJAN INSTITUTE OF TECHNOLOGY (Affiliated to JNTUA & Approved by AICTE) (Accredited by NAAC with ‘A’ Grade) (Accredited by NBA(EEE,ECE&CSE)) Rotarypuram Village, B K Samudram (Mandal) Ananthapuramu-515701

2018-2019 Additive manufacturing Page 1

SRINIVASA RAMANUJAN INSTITUTE OF TECHNOLOGY (Affiliated to JNTUA & Approved by AICTE) (Accredited by NAAC with ‘A’ Grade) (Accredited by NBA(EEE,ECE&CSE)) Rotarypuram Village, B K Samudram (Mandal) Ananthapuramu-515701 DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE This is to certify that this Technical seminar report entitled “Additive Manufacturing Process” being submitted by K MEGHANATH (164G5A0310) in partial fulfillment of the requirement for the award of the degree of Bachelor of Technology in “MECHANICAL ENGINEERING” during the academic year 2018-19.

Project Guide Mr. L. VAMSI KRISHNA REDDY M. Tech

Assistant Professor (Department Of Mechanical Engineering)

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HEAD OF THE DEPARTMENT (PhD)

Dr. S. M. Jameel Basha

M. Tech PhD

Professor (Department Of Mechanical Engineering)

ACKNOWLEDGEMENT We sincerely express our gratitude thanks to Mr. L Vamsi Krishna Reddy Assistant professor for his guidance and encouragement that led to the completion of this report.

We extend our sincere and heartful thanks to Dr. S. M. Jameel Basha

M.Tech,Ph.D

Head of the Mechanical Engineering Department for giving this opportunity to do this work.

We extend our sincere and heartful thanks to Dr. T. Hitendar Sharma

M.Tech, Ph.D

Principal for giving this opportunity to do the report.

We take this occasion to express our acknowledgement to all the faculty members and Non-teaching staff of Mechanical Engineering Department for their co-operation and encouragement throughout our post graduation and to all our friends who have helped in one way or the other.

Finally, we are greatly thankful to our beloved parents for their motivation and encouragement during the project work and made a part in our success.

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ABSTRACT Additive manufacturing (AM), also known as rapid prototyping or 3D printing, generally refers to techniques that produce threedimensional parts by adding material gradually in a layer by layer fashion. In this sense, AM differs fundamentally from forming and subtractive techniques. This special issue intends to put together research and developments in AM, particularly related to new manufacturing processes and/or to alternative feedstock materials and products. Polymer and metal-based raw materials and products have been extensively investigated in AM techniques. Recently, ceramic, glass, and composite materials have been additionally used both in commercial and in innovative AM processes. The material compositions and processing steps used for shaping or finishing the structure of AM products are responsible for final properties and performance. Recent advances in sensors, micromechanics, computational modeling, and simulation have enhanced AM technologies. As complex parts become easier to build and the equipment and skills needed to build them become more and more common, innovative approaches are achievable. Additionally, this evolution opens up new fields of application, moving it from being a prototyping tool to a final product manufacturing process (rapid manufacturing). This special issue explores the development of new products and applications through AM processes. Selected investigations contributed to this issue with original research that analyze feedstock materials, process parameters, and their effects on mechanical, physical, and other properties in prototypes or customized parts fabricated by AM techniques.

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CONTENTS 1. History

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2. Introduction -------------------------------------------- 7-8 3. Steps in 3D printing ----------------------------------- 9-10 4. Classifications ----------------------------------------- 11-15 5. Advantages --------------------------------------------- 16 6. Types of materials used ------------------------------ 17-21 7. Applications ------------------------------------------ 22-24 8. Scope of additive manufacturing -------------------- 25 9. Conclusion --------------------------------------------- 26 10. References ---------------------------------------------- 27

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1.HISTORY The technology for printing physical 3D objects from digital data was first developed by Charles Hull in 1984. He named the technique stereolithography and obtained a patent for the technique in 1986. The same year, he founded 3D Systems and developed the first commercial 3D Printing machine. AM processes for metal sintering or melting (such as selective laser sintering, direct metal laser sintering, and selective laser melting) usually went by their own individual names in the 1980s and 1990s. Nearly all metalworking production at the time was by casting, fabrication, stamping, and machining; even though plenty of automation was applied to those technologies (such as by robot welding and CNC), the idea of a tool or head moving through a 3D work envelope transforming a mass of raw material into a desired shape layer by layer was associated by most people only with processes that removed metal (rather than adding it), such as CNC milling, CNC EDM, and many others.

CHARLES HULL Additive manufacturing Page 6

2.INTRODUCTION The process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies is known as Additive Manufacturing. Synonyms: additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing and freeform fabrication. As an enabling technology AM is used in a broad spectrum of manufacturing.

WHAT IS 3D PRINTING ? 3D printing is a process in which material is joined or solidified under computer control to create a three-dimensional object, with material being added together, typically layer by layer. In the 1990s, 3D printing techniques were considered suitable only for the production of functional or aesthetical prototypes and a more appropriate term was rapid prototyping. Today, the precision, repeatability and material range have increased to the point that 3D printing is considered as an industrial production technology, with the name of additive manufacturing.

RAPID PROTOTYPING Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using threedimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology Additive manufacturing Page 7

CLASSIFICAION OF RAPID PROTOTYPING 1. Subtractive method 2. Additive method

SUBTRACTIVE MANUFACTURING Subtractive manufacturing is a process by which 3D objects are constructed by successively cutting material away from a solid block of material. Subtractive manufacturing can be done by manually cutting the material but is most typically done with a CNC Machine

ADDITIVE MANUFACURING The term ‘additive manufacturing’ was given by the ASTM ( American Society for Testing and Materials) committee. Additive Manufacturing (AM) is the process of making 3D objects from computer model data by joining materials layer by layer under computer control using a 3D printer.

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3.Steps In Additive Manufacturing 1.

Generate a 3D model Draw a 3D model of product on any software such as CAD, Solid Works etc. 2. Generation of STL (Stereolithography) file The STL (stereo lithography) file format is supported by many other software packages; it is widely used for rapid prototyping and computeraided manufacturing (CAM). STL files describe only the surface geometry of a three dimensional object without any representation of color, texture or other common CAD model attributes. *An STL file describes a raw unstructured triangulated surface by the unit normal and vertices (ordered by the right-hand rule) of the triangles using a three-dimensional Cartesian coordinate system.

Fig. STL File 3.

Software slices the 3D model into thin slices

Fig. Slicing of 3D model Additive manufacturing Page 9

Now computer scans this area and give instructions to printer or machine to procced for further operations. 4. Machine builds it layer by layer

5. Cleanup and post curing 6. Surface finishing

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4.CLASSIFICATION OF ADDITIVE MANUFACTURING

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STEREOLITHOGRAPHY (SLA) Stereolithography is a process for creating three-dimensional objects using a computer-controlled laser to build the required structure, layer by layer. It does this by using a resin known as liquid photopolymer that hardens when in contact with the air. • Patented in 1986 • 3D System is the market leader • Highest resolution and smoothness • UV Laser beam cure cross-sections of parts in a liquid batch of photoreactive resin • Subvariants: DLP entire layer projection

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SELECTIVE LASER SINTERING (SLS) This is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal, ceramic or glass powder into the desired 3-D shape. The laser selectively fuses the material by scanning cross sections generated from a 3-D digital description of the part, for example a CAD file. It can be used for both thermoplastics and metal. Powder is fed into a continuous layer. Laser is used to fuse/sinter powder particles layer-by-layer. Produces functional parts. Layer thickness 0.004” or less.

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FUSED DEPOSITION MODELLING (FDM) FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle. The nozzle is heated to melt the material and can be moved horizontally and vertically. The part, or model, is produced by extruding mall beads of thermoplastic material to form layers and the material hardens immediately after extrusion from the nozzle. • Extruder on a cartesian robot • Extrudes thermoplast polymers “spaghetti” • Moderately fast and inexpensive • Stratasys is the market leader • Functional parts, ABS and nylon • Best choice for mechanical engineers and product developers • Can be used for direct digital manufacturing • Systems starting from $14,000

FIG: Fused deposition modelling Additive manufacturing Page 14

LAMINATED OBJECT MANUFACTURING (LOM) In some printers, paper can be used as the build material, resulting in a lower cost to print. During the 1990s some companies marketed printers that cut cross sections out of special adhesive coated paper using a carbon dioxide laser and then laminated them together. In 2005 Mcor Technologies Ltd developed a different process using ordinary sheets of office paper, a tungsten carbide blade to cut the shape, and selective deposition of adhesive and pressure to bond the prototype. There are also a number of companies selling printers that print laminated objects using thin plastic and metal sheets. • Object made by deposition and cutting of layers of tapes • Introduced in 1991 by Helisys Inc of Torrance. • Cubic and Helisys offer this technology • Slow, sharp edges • Research on composites prepregnated moldless manufacturing • Inexpensive depending on accuracy, large scale models possible • Slow and inaccurate (knives vs lasers)

FIG: Laminated object manufacturing Additive manufacturing Page 15

5.ADVANTAGES OF ADDITIVE MANUFACTURING Adopted 3D printing as a way to increase innovation. Mechanical properties of products are more as compared to that which are made by conventional process. Reduce costs and speed up the process. 3D models of buildings can be easily created and edited as plans develop something that used to take a significant amount of time to make. Freedom of creation of more complex geometries. More Complex Geometries Internal Features & Structures Parts Consolidation Enables business models used for 2D printing, such as for photographs, to be applied to physical components The unattainable triangle of speed, price and quality. Eliminates drivers to concentrate production “Design Anywhere / Manufacture Anywhere” is now possible Manufacture at the point of need rather than at lowest labor location Changing “Just-in-Time Delivery” to “Manufactured-onLocation Just-in-Time”

DISADVANTAGES OF ADDITIVE MANUFACTURING Construction of large parts is not possible but research are going to make large machines. Machine cost is high The current slow print speed of 3D printers limits their use for mass production. Additive manufacturing Page 16

6.TYPES OF MATERIALS USED IN ADDITIVE MANUFACTURING There are so many materials you can choose from when it comes to 3D printing that it’s often tough to decide on the right one. But do not fear! Tinkercad’s Materials Guide is here! Our easy-to-read guide will help you select the perfect material based on a few important factors, like type, minimum thickness, texture and the all-important cost. Whether you’re looking to 3D print a prototype or a unique 3D gift, our Materials Guide will help guide you through the process!

NYLON: (Polyamide) 

    

Also called White, strong & flexible / Durable plastic / White plastic Strong and flexible plastic 1mm minimum wall thickness Naturally white, but you can get it colored About 10 layers per 1mm Made from powder Additive manufacturing Page 17



Alumide = Polyamide + Aluminum



ABS: (Home printers)     

Strong plastic like legos are Made from spaghetti like filament Many color options About 3 layers per 1mm 1mm minimum wall thickness

RESIN: (Multiple options) 

  

Also called White-, Black-, Transparent detail / White detail resin / High detail-, Transparent-, Paintable Resin Rigid and a bit delicate Liquid Photopolymer cured with UV light White, black & transparent most typical colors Additive manufacturing Page 18

 

About 10 layers per 1mm 1mm minimum wall thickness



STAINLESS STEEL:     

Very strong material Made with multiple steps or from powder directly Colouring options like gold and bronze plating About 6 layers per 1mm 3mm minimum wall thickness

GOLD & SILVER:    

Strong materials Made from wax and then casted About 10 layers per 1mm 0.5mm minimum wall thickness Additive manufacturing Page 19

TITANIUM:    

Strongest material Direct metal laser sintering About 30 layers per 1mm 0.2mm minimum wall thickness

CERAMIC:     

Rigid & delicate First ceramic is printed then surface is glazed Ceramic white, glaze typically white About 6 layers per 1mm 3mm minimum wall thickness Additive manufacturing Page 20

GYPSUM:     

Also called Sandstone / Rainbow ceramics / Multicolor Rigid & delicateMade from powder Naturally white, but you can get it with colors About 10 layers per 1mm 2mm minimum wall thickness

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7.APPLICATIONS OF ADDITIVE MANUFACTURING Medical applications

Advances in research Product prototyping

Historic Preservation

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Architectural Engineering Construction

Advanced Manufacturing

Food Industries

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Automotive

Accessories

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8.SCOPE OF ADDITITIVE MANUFACTURING

First ever 3-D printed car. Urbee is the first prototype car ever to have its entire body 3D printed with an additive process. All exterior components, including the glass panel prototypes, were created using Dimension 3D Printers and Fortus 3D Production Systems at Stratasys' digital manufacturing service.

Fig. First 3D printed car 3-D printed Buildings? Architect Enrico Dini is planning to build the first ever 3-D printed building with the help of fellow architects. Additive manufacturing Page 25

9.CONCLUSION The world is forever changing with the help of 3D printing. The use of 3D printing for medicinal and engineering purposes today is beyond astonishing but what the future holds is unknown, however It is certain that additive layer manufacturing will be a large corporate in solving our problems. 3D printing really is limitless and only the surface has been scratched, there is still much more to be uncovered. 3D is forever unpredictable. “If a picture is worth a thousand words… A prototype is worth a thousand pictures.’’

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REFERENCES  Lipson, Hod, Francis C. Moon, Jimmy Hai, and Carlo Paventi. (2007) "3D-Printing the History of Mechanisms." Journal of Science.  www.google.com  Modern Manufacturing Methods By Mikell P.Groover

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