Design and analysis of sla printer
- 1. ME 54600 CAD/CAM Tools and Application Fall 2016 Prof. Daniel Aw Prof. Hazim El-Mounayri PROJECT FINAL DESIGN AND ANALYSIS OF A STEREOLITHOGRAPHY PRINTER Satyajeet Udavant IUPUI, Indianapolis
- 2. ME 546 CAD/CAM satyajeet udavant 2 PARTICULARS Sr no Topic Page 1 OBJECTIVE 3 2 INTRODUCTION 3 3 SUMMARY OF ACCOMPLISHMENTS 6 4 CAD 6 5 Analysis 9 6 Meshing 10 7 Constraints 13 8 Results from modal analysis 14 9 CFD Analysis 19 10 Results and conclusion 20 11 References 21
- 3. ME 546 CAD/CAM satyajeet udavant 3 OBJECTIVE The objective is to have a sound knowledge of the procedure start to finish in making of a 3d printer with special focus on the following: I. Design components of SLA 3d printer. II. Assembly. III. Finite Element Analysis - Using Ansys for structural IV. Finite Element Analysis - CFD INTRODUCTION SLA printer sold since 1988 and costs from 5,000 USD to 450,000 USD. In this process a polymer, creating a solitary layer of set tar - the principal cut of the question under development. The underlying layer is then brought down incrementally by the stature of the following cut, where upon the layer is recovered with pitch and another is followed on top of it. This methodology is rehashed until the whole part is manufactured. By space resolved laser induced polymerization of a liquid monomer into a solid polymer complex shapes can be quickly produced in SLA. Recently the technology is developed in different areas. Like DLP, where a complete plane is scanned as compared to line tracing of laser. CLIP, is even faster as it uses LED as photon source for polymerization. The solid modelling software CREO Parametric is a software used to create the various part modules and is also used for assembling those parts together to create an appropriate mechanism. For the final project of the 3 credit course, I worked for all the three aspects of a product development to make the project more complete. 1. Design – The SLA printer under consideration is similar to that of any vat polymerization printer. Ex Fromlabs 2. Most of the design parameter and data is used from online sources. The printer designed is similar to that of the BeamMaker.
- 4. ME 546 CAD/CAM satyajeet udavant 4 2. Assembly- the various parts that are created are assembled so that it can be tested for the further analysis. 3. Analysis – we used Ansys Workbench for the structural and modal analysis. 4. Materials: For this project the ideal materials needed and required considering overall aspect of the printer is fiberglass. Fiberglass (or fibreglass) is a type of fiber-reinforced plastic where the reinforcement fiber is specifically glass fiber. The glass fiber may be randomly arranged, flattened into a sheet (called a chopped strand mat), or woven into a fabric Fiberglass batt insulation is made by forming spun-glass fibers into batts. At an insulation plant, the product feedstock is weighed and sent to a melting furnace. The raw materials are melted in a furnace at very high temperatures. To be used in fiberglass, glass fibers have to be made with very low levels of defects. Fiberglass is a strong lightweight material and is used for many products. Although it is not as strong and stiff as composites based on carbon fiber, it is less brittle, and its raw materials are much cheaper.
- 5. ME 546 CAD/CAM satyajeet udavant 5 Relevant information was also taken by measuring the outside dimensions of the SLA printer Formlabs 2 available in Additive Manufacturing Lab, SL 009, IUPUI. Following is the fig of the printer whose dimensions are measured to be as 58 x 58 x 72 cm outside build of Form 2 This printer is available in AM lab. All the different resins and post processes and curing is all available for students use.
- 6. ME 546 CAD/CAM satyajeet udavant 6 SUMMARY OF ACCOMPLISHMENTS CAD Cad designs for this projects are as follows. 1. Magnifying glass housing 2. Mirror support
- 7. ME 546 CAD/CAM satyajeet udavant 7 3. Side structures and supports 4. Support for wall structure for magnifying glass
- 8. ME 546 CAD/CAM satyajeet udavant 8 5. Front wall structure 6. Back support and structure 7. Lead screw
- 9. ME 546 CAD/CAM satyajeet udavant 9 ASSEMBLIES These are few of the parts and the assembly used for the analysis as follows: Analysis For analysis we used three different types of meshing for better results Printer in Ansys- before meshing
- 10. ME 546 CAD/CAM satyajeet udavant 10 Meshing comparison 1. Mesh size coarse and medium smoothness Here the following parameters are used for meshing
- 11. ME 546 CAD/CAM satyajeet udavant 11 2. Element size medium and medium smoothness And the mesh parameters are follows
- 12. ME 546 CAD/CAM satyajeet udavant 12 3. Fine and high smoothing And parameters used for these are
- 13. ME 546 CAD/CAM satyajeet udavant 13 Constraints Displacement Constraints were applied at the bottom of the printer. Bottom displacement kept to be zero, the blue parts are high lightened in figure Max Modes
- 14. ME 546 CAD/CAM satyajeet udavant 14 Results from modal analysis Total deformations and the displacement are as follows
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- 18. ME 546 CAD/CAM satyajeet udavant 18 We can conclude that the modal is safe as in all the results are within the safe limits.
- 19. ME 546 CAD/CAM satyajeet udavant 19 CFD Analysis CFD and heat transfer phenomena are carried out with finite element methods. It is applied in order to improve element shape. Since some of the curing process are expensive by using laser device, if any mistake happens during the application of laser device it cost a lot because of effort, material, time. Because of this reason finite element method simulation has been applied in studying, one of the most important device’s characteristics such as exit cooling fluid’s temperature. Temperature field simulation: Since cooling fluid’s temperature influence on appropriate lase device functioning, it involves computational fluid dynamics (CFD). The simulation was done, considering the fact that it should get better by discovering errors and miss-functioning of laser device before manufacturing its components from the expensive required materials. All the sharp edges in the printing model should be chamfered, small sized regions of material should be removed. Then only the FEM gives out good results. The velocity field of cooling fluid can significantly influence the temperature distribution. Fig: Model Fig: Model mesh with a detailed view of the inflated surface.
- 20. ME 546 CAD/CAM satyajeet udavant 20 Fig: Temperature distribution field-with streamlines CONCLUSION 1.1. The parts were successfully modelled to the required dimensions and assembled using the right constraints. 1.2. The material selection and corresponding meshing results were achieved. 1.3. The Assembly of the parts are completed 1.4. The Ansys analysis of the 3d printer for modal frequency is successfully completed and found to be within the safe limits. 1.5. CFD analysis was completed successfully Reference Applied Finite Element Method Simulation in 3D Printing M. Iliescu, E. Nuţu, B. Comănescu https://formlabs.com/ http://www.fibreglast.com/ https://sites.google.com/site/dkenglishednotes/sla-research-paper