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Additive Manufacturing

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ADDITIVE

MANUFACTURING
Mr.M.Mani, M.E., (Ph.D)
Assistant Professor,
Department of Mechanical Engineering,
Sri Ranganathar Institute of Engineering and
Technology, Coimbatore.
Manufacturing
 The process of converting raw materials into finished products.
 Manufacturing is a very broad activity, encompassing many
functions – everything from purchasing to quality control of the
final product.
 Chemical or Physical transformation of the materials, substances
or components into some new products.
 Manufacturing is a value addition activity to the raw materials,
substances/components.
 Manufacturing is a process through which products are made
through various production activities.
 Manufacturing is the use of machines, tools and labor to make
things for use or sale.
Conventional Manufacturing Process
 In conventional machining process, the material is removed by the direct contact between tool and
workpiece.
 The energy is utilized to rotate either workpiece or tool, and the cutting tool should be harder than
workpiece (35-50% more hardness).
 Traditional, also termed conventional, machining requires the presence of a tool that is harder than the
workpiece to be machined. This tool should be penetrated in the workpiece to a certain depth. Moreover, a
relative motion between the tool and workpiece is responsible for forming or generating the required shape.
Tools have a specific number of cutting edges of a known geometry.
Conventional Manufacturing Process
Disadvantages / Limitation of
Conventional Machining Process:
 Less surface finish.
 They can't machined complex shapes.
 More tool wear.
 Lower dimensional accuracy.
 Noisy operation causes sound pollution.
Need of Advanced Manufacturing
Process
 Increased level of quality
 Boost productivity
 Gives way to innovation
 Reduced production time with digital manufacturing
Need of advanced manufacturing process
Advanced Manufacturing Process

Advanced manufacturing is defined as “the use of innovative technologies to create existing


products and the creation of new products, including production activities that depend on
information, automation, computation, software, sensing, and networking”.
Evolution of Modern Manufacturing
Types of Advanced Manufacturing

 Additive manufacturing
 Advanced/Composite materials
 Robotics/automation
 Laser machining/welding
 Nanotechnology
 Network/IT integration
Advanced Manufacturing Industries

 Electric vehicles
 Robotics
 Automobiles
 Medical devices
 Pharmaceuticals
 Rapid prototyping
Additive Manufacturing
 The term “additive manufacturing” references technologies that grow three-dimensional
objects one superfine layer at a time.
 Each successive layer bonds to the preceding layer of melted or partially melted material.
 Objects are digitally defined by computer-aided-design (CAD) software that is used to
create .stl files that essentially "slice" the object into ultra-thin layers.
 This information guides the path of a nozzle or print head as it precisely deposits material
upon the preceding layer. Or, a laser or electron beam selectively melts or partially melts in
a bed of powdered material. As materials cool or are cured, they fuse together to form a
three-dimensional object.
Additive Manufacturing
Additive vs. Subtractive Manufacturing
Metal Matrix Additive Manufacturing
Products
Additive Manufacturing Products-
Plastics
Additive Manufacturing Types
Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM)
 FDM Technology developed S.Scott crump in the late 1980’s
 Material type: Solid (Filaments - polymeric)

 Supply material to extrusion nozzle in wire form

 Nozzle heated and melted the material and can be move both Hrz & Ver directions by NC
mechanism directly controlled by CAD software
Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM)

 More recent FDM include two nozzles one for part material and other for support material

 Part materials: Thermoplastics such as acrylonitrile butadiene styrene (ABS), PA,


Polycarbonate, medical grade plastic, Elastomers

 Support materials are water soluble (WSS), Support structure can be removed/dissolved in
heated sodium hydroxide solution with the assistance of ultrasonic agitation
FDM Machines
Fused Deposition Modeling (FDM)
Process of FDM

The process of FDM is relatively simple and fast but its use is limited to thermoplastic materials

Step 1- The thermoplastic material in the form of filament (plastic filament-like wire) is heated to
just above its solidification temperature

Step 2 - The extrusion head (coil carries the nozzle) is heated and moves according to the pattern
(CAD) of the cross section (X,Y) (Hrx/Ver) of each layer of the part. It controls the motion or flow
of the material. Movement from the nozzle is actually controlled by a design generated by a
computer aided manufacturing software.
Process of FDM

Step 3 - Small beads from the melted materials leave the heated misting nozzle to form
layers. The material is extruded on the foundation or previously built layer. As it is
extruded, it is cooled and thus solidifies (materials hardens) to form the required pattern of
part.

Step 4 - Repeat 2 and 3 until the top layer of the part is generated

Step 5 - Part finishing may be required


Advantages

 No post curing.

 Variety of materials.

 Easy material changeover.

 Office environment friendly.

 Low end, economical machines.


Limitations

 Not good for small features, details and thin walls.


 Surface finish.
 Supports required on some materials / geometries.
 Support design / integration / removal is difficult.
 Slow on large / dense parts.
Application

 Models for conceptualisation and presentation

 Prototypes for design, analysis and functional testing

 Patterns and masters for tooling. Models can be used as patterns for investment casting, sand
casting and moulding

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