24-09-2014, 02:18 PM
ABSTRACT/GIST OF THE PROJECT DONE To make a Prototype of Flange Forging Maritate with ABS+ material Prototype Making: 3D Printer:- Additive manufacturing or 3D printing is a process of making a three- dimensional solid object of virtually any shape from a digital model.3D printing is achieved using aadditive process, where successive layers of materials are laid down in different shapes.3D printing is considered distinct from traditional machining techniques, which mostly rely on the removal of material by methods such as cutting or drilling (subtractive process).. The technology is used for both prototyping and distributed manufacturing in jewellery, footwear, industrial design, architecture, engineering and construction (AEC), automotive, aerospace, dental and medical industries, education, geographic information systems, civil engineering and many other fields. The term additive manufacturing refers to technologies that create through a sequential layering process.Objects that are manufactured additively can be used anywhere throughout the product life cycle from pre-prod
8. PROJECT REPORT
1.1 To make a Prototype of Flange Forging Maritate
1.2 Details of the project:
8.2.1 Project introduction
The basic aim of the project is to study, analyze and modify the design of flange forging maritate so as to save the material loss and also to increase the rate of manufacturing process. The flange which industry made is of old design and now need some modifications as per the need of latest market demands.In this project, we would first go through the parent design given to us then we would do some modifications with the help of CAD software. Once the final design is ready, we would make prototype of the same using a 3D modelling printer which would help us in having a better over understanding of the component and thus also help us to know how much material would be used in making the new redesigned component. Once the component is made, we would analyze the new component with older one and thus attaining the final overall result i.e. to minimize the loss of the material.
8.2.2 Overview of the flange forging maritate-:
This component is use in power transmission in heavy vehicle. It is attached to the drive shaft which further transmits the power to the rear wheels.
Application-:
1. It is use in automobiles.
2. It is use in heavy vehicle for power transmission.
3. For example trucks and buses.
Flange Forging Maritate
Objective and scope :
The main objective of our project is to study new technologies like CAD/CAM (design) and 3D printing technique (prototyping), the whole course of our project covers designing and prototype making. These technologies (CAD/CAM, 3D printer) are very beneficial for today’s growth oriented and fast moving industries.
Applications of RPT (Rapid prototyping)
· Industrial uses
· Rapid prototyping
· Rapid manufacturing
· Mass customization
· Domestic and hobbist uses
· 3D printing services
· Research
8.2.3 Project Plan
Hardware And Software Requirements:
Software used :
· CREO 2.0(for design and die development)
· NX CAM (for prototype making)
Hardware used :
· Design machines (to work with CREO 2.0 and NX)
· 3D Printer (Dimension 1200es 3D Modeling Printers)
Technology used:
· Creo 2.0
· NX ( CAM )
· 3D printer (dimension 1200es)
8.3 Prototype Making:
3D Printer:-
Additive manufacturing or 3D printing is a process of making a three- dimensional solid object of virtually any shape from a digital model.3D printing is achieved using a additive process, where successive layers of materials are laid down in different shapes.3D printing is considered distinct from traditional machining techniques, which mostly rely on the removal of material by methods such as cutting or drilling (subtractive process).
A material printer usually performs 3D printing processes using digital technology.Since the start of twenty-first century there has been a large growth in the sales of these machines and their price has dropped substantially.
The technology is used for both prototyping and distributed manufacturing in jewellery, footwear, industrial design, architecture, engineering and construction (AEC), automotive, aerospace, dental and medical industries, education, geographic information systems, civil engineering and many other fields.
The term additive manufacturing refers to technologies that create through a sequential layering process.Objects that are manufactured additively can be used anywhere throughout the product life cycle from pre-production (i.e. rapid prototyping) to full scale production (i.e. rapid manufacturing), in addition to tooling applications and post production customization.
3D Printer
General principles:-
1. Modelling
Additive manufacturing takes virtual blueprints from computer aided design (CAD) or animation modelling software and slices them into digital cross-section for thmachind to successively use as a guideline for printing. Depending on the machine used , material or binding material is deposited on the build bed or platform until material/binder layering is complete and the final 3D model has been printed. It is a WYSIWYG process where the virtual model and the physical model are almost identical.
A standard data interface between CAD software and the machines is SLT file format. An SLT file approximates the shape of a part or assembly using triangular facets. Smaller facets prodeuce a higher quality surface. PLY is a scanner generated input file format, and VRML (or WRL) files are often used as input for 3D printing technologies that are able to print in full color.
2. Printing
To perform a print, the machine reads the design from .stl file and lays down successive layersofiquid.powder, paper or sheet material to build themodel from a series if cross sections. These layers, which correspond to virtual cross sections from the CAD model, are joined together or automatically fused to create a final shape. The primary advantage of this technique is its ability to create almost any shape or geometric feature.
Printer resolution describes layers thickness and X-Y resolution in dpi (dots per inch), or micrometers. Typical layer thickness is around 100 micrometers(0.1mm), although some machines such as Object Ccnexx series and 3D systems’ Project series can print layers as thick as 16 micrometers. X-Y resolution is comparable to that of laser printers. The particles(3D dots) are around 50to 100 micrometers(0.05-0.1mm)in diameter.
Construction of models from contemporary methods can take anywhere from several hours to several days. Depending on the model method used and size and complexity of the model. Additive systems can typically reduce this thime to few hours, although it varies widely depending on the type of machine used and the size and number of models being produced simultaneously.
Traditionally techniques like injection modelling can be less expensive for manufacturing polymer products in high quantities, but additive manufacturing can be faster, more flexible and less expensive when producing relatively small quantities of parts. 3D rpinters give designers and concept development teams the ability tp produce parts and concept models using a desktop size printer.
3. Finishing
Though the printer produced resolution is sufficient for many applications, printing a slightly oversized version of the desired product in standard resolution, and then removing material with a higher resolution subtractive process can achieve great precision.
Some additive manufacturing techniques are capable of using multiple materials in the course of construction parts, some are able to print in multiple colors and color combination simultaneously. Some also utilize supports when building, supports are removable or dissolvable upon completion of the print, and are used to support overhanging features during construction.
8.3.1 Procedure for making prototype:
1. Firstly a 3D model is created in Creo 2.0, which is in .prt format.
2. The .prt (Part) model is converted into .STL (Stereo Lithographic) format so that this 3D model can work with Catalyst software which is used for 3D printing.
Specifications used in Catalyst software:-
Model Interior:- Sparse High Density
Support File:- SMART
STL units:-Millimeters (mm)
3D printer Specifications:
Envelope Temperature:- 75o C
Nozzle Temperature:- 300o C
8.3.2 Specifications of Prototype:-
Scale
0.35
Model Material
21.79 cm3
ABS+ material
Supporting Material
4.32 cm3
Time
1 Hours 49 Minutes
Prototype of Flange Forging Maritate
8.3.3 Additive processes:
A number of additive processes are now available. They differ in way layers are deposited to create parts and in materials that can be used. Some methods melt or soften material to produce the layers, e.g selective laser sintering (SLS) and fused deposition modelling (FDM), while other cure liquid materials using different sophisticated techniques, e.g stereo lithography (SLA). With laminated object manufacturing(LOM), thin layers are cut to sharpen and join together (e.g paper. Polymer. And metal). Each method has its own advantages nad disadvantages, and some companies consequently offer a choice between powder and polymer for the material from which the object is built. Some companies use standars, off-the-self business paper as the build material to produce a durable prorotype. The main consideration in choosing a machine are generally speed, cost of 3D printer, cost of printed prototype, and cost and choice of materials and color capabilities.
Printers that work directly with metals are expensive, in some cases, however, less expensive printers can be used to make a mould, which is then used to make metal parts.
Type
Technologies
Materials
Extrusion
Fused deposition modelling (FDM)
Thermoplastics (e.g PLA,ABS), HDPE, eutectic metals,sdible materials.
Wire
Electron beam freeform fabrication (EBF)
Almost any metal alloy
Granular
Direct metal laser sintering (DMLS)
Almost any metal alloy
Electron beam melting (EBM)
Titanium alloys
Selective heat sintering (SHS)
Thermoplastic powder
Selective laser sintering (SLS)
Thermoplastics, metal powders,ceramic powders
Powder bed and inkjet 3D printing, Plaster-based 3D printing (PP)
Plaster
Laminated
Laminated object manufacturing (LOM)
Paper, metal foil, plastic film
Light polymerised
Stereolithography (SLA)
Photopolymer
Digital light processing (DLP)
Photopolymer
8.3.4 Implementation Models: