Design for Additive Manufacturing - Introduction
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The document discusses additive manufacturing and design for additive manufacturing. It covers topics like understanding the principles of additive manufacturing processes, differentiating between additive manufacturing methods, designing parts for additive manufacturing, and considering post-processing steps. Key points emphasized are the importance of designers considering the entire additive manufacturing process when designing parts, including machining and other post-processing requirements, and collaborating with manufacturing engineers to optimize part orientation and minimize support structures.
![UNIT
4
Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 11
Material Requirement
The aerospace sector relies heavily on machined forged and billet structures for high-value
structural systems. This manufacturing methodology provides high certainty in final
component quality, as billet materials are readily certified for porosity and microstructure but
adds substantial direct manufacturing costs and induced costs due to high production lead
times.
Forging requires the expensive design, manufacture, and trialling of preforming dies and
billet machining is inherently expensive with typical buy-to-fly ratios2 estimated at 20:1. For
example, a final product with a mass of 10 kg would require 200 kg of stock materials as
discussed in [16]. Others claim this ratio is closer to 40:1 [17]. The unused material is waste
and is recycled or reprocessed if possible, adding extensive costs to all projects.](https://image.slidesharecdn.com/unit4-240310173312-6e8823aa/85/Design-for-Additive-Manufacturing-Introduction-11-320.jpg)
![Aircraft Oil
Sump Housing
Material: Titanium (Ti6Al4V)
Size: Diameter of ~ 8”
Height of ~ 10”
Temp: 400 oC / 752 F
1. Using the rating scale on the DFAM scorecard, how strong a candidate is this
part for additive manufacturing (enter overall total)? [5%]
3. What modifications would you make to the design of this part to improve its
chances of success with additive manufacturing? [10%]
2. What is the best additive manufacturing process for this part, and why did
you choose this process? [5%]
19 ± 5
Laser powder bed fusion
Metal part, needs to withstand high temperatures, internal
channels with significant detail
Add generous fillets to make structure self-supporting
Ensure internal channels are self-supporting, either by
staying below 5mm, or changing shape to teardrop](https://image.slidesharecdn.com/unit4-240310173312-6e8823aa/85/Design-for-Additive-Manufacturing-Introduction-69-320.jpg)
![Auto Engine
Mount Bracket
Material: Steel
Size: 8” x 4” x 1”
Temp: 100 oC / 212 F
1. Using the rating scale on the DFAM scorecard, how strong a candidate is this
part for additive manufacturing (enter overall total)? [5%]
3. What modifications would you make to the design of this part to improve its
chances of success with additive manufacturing? [10%]
2. What is the best additive manufacturing process for this part, and why did
you choose this process? [5%]
18 ± 5
Laser powder bed fusion
Load bearing, critical-to-function component. Laser powder
bed fusion properties (post HIP and heat treatment) likely to
meet requirements.
Add cellular structures or use topology optimization to reduce
mass, perform a stress analysis to validate performance
Provide extra stock around mating locations to machine later for
improved tolerances](https://image.slidesharecdn.com/unit4-240310173312-6e8823aa/85/Design-for-Additive-Manufacturing-Introduction-70-320.jpg)
![Helicopter
Shroud Cover
Material: Titanium (Ti6Al4V)
Size: 15” x 8” x 1”
Temp: 100 oC / 212 F
1. Using the rating scale on the DFAM scorecard, how strong a candidate is this
part for additive manufacturing (enter overall total)? [5%]
3. What modifications would you make to the design of this part to improve its
chances of success with additive manufacturing? [10%]
2. What is the best additive manufacturing process for this part, and why did
you choose this process? [5%]
Switching this material to a polymer like ULTEM (PEI) and
using Fused Deposition Modeling would work well since this
is not a load-bearing component and temperature maximum
is well within ULTEM specifications
Add stiffening ribs, increase fillets around corners to
mitigate stress concentration
19 ± 5](https://image.slidesharecdn.com/unit4-240310173312-6e8823aa/85/Design-for-Additive-Manufacturing-Introduction-71-320.jpg)
![1. Using the rating scale on the DFAM scorecard, how strong a candidate is this
part for additive manufacturing (enter overall total)? [5%]
3. What modifications would you make to the design of this part to improve its
chances of success with additive manufacturing? [10%]
2. What is the best additive manufacturing process for this part, and why did
you choose this process? [5%]
Aircraft Engine
Stator Assemblies
Material: Inconel 718
Size: Width:~9.9”
Height: ~6”
Temp: 350 oC / 662 F
Laser powder bed fusion
Metal part, needs to withstand high temperatures and failure
critical rotary part. Geometry and surface finish of stator
blades are important
Add generous fillets around housing, machine mounting
holes after print
21 ± 5](https://image.slidesharecdn.com/unit4-240310173312-6e8823aa/85/Design-for-Additive-Manufacturing-Introduction-72-320.jpg)
![Aircraft bearing
housing
Material: Grey Cast Iron
Size: Outer Diameter ~17”
Inner Diameter 10”
Temp: 200 C / 392 F
1. Using the rating scale on the DFAM scorecard, how strong a candidate is this
part for additive manufacturing (enter overall total)? [5%]
3. What modifications would you make to the design of this part to improve its
chances of success with additive manufacturing? [10%]
2. What is the best additive manufacturing process for this part, and why did
you choose this process? [5%]
26 ± 5
Laser powder bed fusion (large size machine needed)
Metal rotating part, likely failure critical. Mating surfaces and
clearances of high importance, needs process with high
resolution.
Build this as an assembly of two components with stock
material to machine to precise tolerances for bearing fit](https://image.slidesharecdn.com/unit4-240310173312-6e8823aa/85/Design-for-Additive-Manufacturing-Introduction-73-320.jpg)
Design for Additive Manufacturing - Introduction
- 1. UNIT 4 1 ADDITIVE MANUFACTURING CAD in Additive Manufacturing
- 2. UNIT 4 Mr. Kiran Wakchaure Design for Additive Manufacturing Session Content SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 2 Able to understand and apply basic concept of Design for Additive Manufacturing in real life application Session Outcome ADDITIVE Manufacturing
- 3. UNIT 4 Mr. Kiran Wakchaure SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 3 Course Content ADDITIVE Manufacturing
- 4. UNIT 4 Mr. Kiran Wakchaure SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 4 Course Outcomes CO. No. COURSE OUTCOME (S) BLOOM’S TAXONOMY Level Descriptor 1 Understand the principles and significance of additive manufacturing processes in prototyping and functional part fabrication. 2 Understand 2 Differentiate between additive manufacturing methods based on materials, energy sources, costs, and limitations. 3 Apply 3 Study effects of process parameters on (mechanical characterization of 3D printed parts) material consolidation and solidification rates in FDM, SLS, and 3D printing technologies. 3 Apply 4 Design a 3D part and demonstrate proficiency in using slicing, part orientation, and support generation for additive manufacturing of complex geometries. 3 Apply 5 Apply heat treatment and micro-finishing methods to improve mechanical properties and surface finish of additively manufactured components. 3 Apply 6 Apply the knowledge of Additive Manufacturing to precisely manufacture the given component 3 Precision (Dave’s) 7 Adoption of industry standards and academic integrity for report preparation. 4 Adopt (Krathwohn’s) ADDITIVE Manufacturing
- 5. UNIT 4 Mr. Kiran Wakchaure Textbooks: 1. Gibson, I., Rosen, D.W. and Stucker, B., “Additive Manufacturing Methodologies: Rapid Prototyping to Direct Digital Manufacturing”, Springer, 2010. 2. Chua, C.K., Leong K.F. and Lim C.S., “Rapid prototyping: Principles and applications”, second edition, World Scientific Publishers, 2010. 3. Liou, L.W. and Liou, F.W., “Rapid Prototyping and Engineering applications: A toolbox for prototype development”, CRC Press, 2011. 4. Kamrani, A.K. and Nasr, E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006. Reference Books: 1. Hilton, P.D. and Jacobs, P.F., “Rapid Tooling: Technologies and Industrial Applications”, CRC press, 2. D.T. Pham, S.S. Dimov, Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and Rapid Tooling, Springer 2001. 1. Groover Mikell P, Fundamentals of Modern Manufacturing; 2nd Ed., 2004, 670 Gro-04 2. Milewski, J.O., 2017. Additive manufacturing of metals. Cham: Springer International Publishing. 3. Leach, R. and Carmignato, S. eds., 2020. Precision Metal Additive Manufacturing. CRC Press. References SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 5 ADDITIVE Manufacturing
- 6. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 6 Additive Manufacturing
- 7. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 7 Additive Manufacturing
- 8. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 8 Additive Manufacturing
- 9. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 9 Learning Outcomes Apply the DfAM scorecard in assessing the appropriateness of a part for additive manufacturing, while also recalling design constraints and considerations that drive modifications to parts that were not originally designed for additive manufacturing processes. Explain which additive manufacturing design strategy is best suited to different applications. Describe the various factors that influence whether a part is a good candidate for additive manufacturing. Identify key manufacturing considerations when designing for additive manufacturing. Manufacturing in the aerospace sector is subject to numerous interacting technical and economic objectives of: functional performance, lead time reduction, lightweighting, complexity, cost management, and sustainment. Each of these objectives have strong relationships to one another and considerations from each factor must be considered carefully when selecting an optimal design solution.
- 10. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 10 Learning Outcomes Manufacturing in the aerospace sector is subject to numerous interacting technical and economic objectives of: functional performance, lead time reduction, lightweighting, complexity, cost management, and sustainment. Each of these objectives have strong relationships to one another and considerations from each factor must be considered carefully when selecting an optimal design solution.
- 11. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 11 Material Requirement The aerospace sector relies heavily on machined forged and billet structures for high-value structural systems. This manufacturing methodology provides high certainty in final component quality, as billet materials are readily certified for porosity and microstructure but adds substantial direct manufacturing costs and induced costs due to high production lead times. Forging requires the expensive design, manufacture, and trialling of preforming dies and billet machining is inherently expensive with typical buy-to-fly ratios2 estimated at 20:1. For example, a final product with a mass of 10 kg would require 200 kg of stock materials as discussed in [16]. Others claim this ratio is closer to 40:1 [17]. The unused material is waste and is recycled or reprocessed if possible, adding extensive costs to all projects.
- 12. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 12 AM Process Selection
- 13. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 13 Polymer AM
- 14. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 14 Metal AM
- 15. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 15 AM Constraints
- 16. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 16
- 17. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 17
- 18. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 18
- 19. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 19
- 20. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 20
- 21. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 21
- 22. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 22
- 23. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 23
- 24. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 24 Importance of considering post-processing steps after 3D printing in additive manufacturing. These steps include machining, inspection, and metrology. The focus is on understanding how the design of a 3D-printed part can influence these downstream processes. Reasons for Machining in Additive Manufacturing: • Precision requirements: Sometimes, you may need to drill holes or create features with higher precision than what 3D printing can achieve. • Thread tapping: For adding threads to parts. • Surface quality improvement: When certain regions of the part require a smoother finish. • Inspection and metrology: To measure dimensions and ensure parts are within tolerances. Machining Considerations in Additive Manufacturing
- 25. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 25 Machining Considerations in Additive Manufacturing
- 26. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 26 Machining Considerations in Additive Manufacturing
- 27. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 27 Machining Considerations in Additive Manufacturing
- 28. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 28 Machining Considerations in Additive Manufacturing
- 29. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 29 Machining Considerations in Additive Manufacturing
- 30. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 30 Designer's Role in Orientation and Support Minimization: • Designers play a crucial role in determining the orientation of parts to minimize support requirements. • Software tools can assist, but designers need to collaborate with manufacturing engineers to find the best solutions. • The orientation choice impacts material properties, build time, and cost. • Conclusion: • Designers must consider the entire additive manufacturing process, including post- processing steps like machining. • Orientation is a critical factor influencing supports, surface quality, material properties, build efficiency, and cost. • Collaboration between designers and manufacturing engineers is essential for optimizing part design for additive manufacturing. Orientation in Additive Manufacturing
- 31. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 31 Designer's Role in Orientation and Support Minimization: • Designers play a crucial role in determining the orientation of parts to minimize support requirements. • Software tools can assist, but designers need to collaborate with manufacturing engineers to find the best solutions. • The orientation choice impacts material properties, build time, and cost. • Conclusion: • Designers must consider the entire additive manufacturing process, including post- processing steps like machining. • Orientation is a critical factor influencing supports, surface quality, material properties, build efficiency, and cost. • Collaboration between designers and manufacturing engineers is essential for optimizing part design for additive manufacturing. Orientation in Additive Manufacturing
- 32. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 32
- 33. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 33 Orientation in Additive Manufacturing
- 34. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 34
- 35. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 35 Orientation in Additive Manufacturing
- 36. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 36 Orientation in Additive Manufacturing
- 37. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 37 Orientation in Additive Manufacturing
- 38. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 38 Orientation in Additive Manufacturing
- 39. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 39 Orientation in Additive Manufacturing
- 40. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 40 DFAM staircase
- 41. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 41 DFAM staircase DFAM Staircase: The DFAM staircase is a framework that outlines four levels of additive manufacturing application: Level 1 - Rapid Prototypes and Tooling: This level involves creating low-volume parts for prototyping or manufacturing tools, such as molds or fixtures. Level 2 - Direct Part Replacement: At this level, existing parts that were not originally produced with additive manufacturing are recreated using 3D printing while maintaining the same design. Level 3 - Part Consolidation: Part consolidation aims to simplify complex assemblies by combining multiple components into a single 3D-printed structure, reducing the need for fasteners and mating surfaces. Level 4 - DFAM Optimized: The top level focuses on optimizing designs for additive manufacturing, utilizing techniques such as topology optimization and cellular materials to maximize the benefits of AM. These designs are often impossible or highly inefficient to manufacture using traditional methods.
- 42. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 42 DFAM staircase Benefits of Each Level: The lecture highlighted the potential benefits at each level of the DFAM staircase. These benefits include reduced production costs, shorter lead times, simplified assemblies, reduced material usage, improved product reliability, and mass customization. Designers' Role: Designers play a pivotal role in realizing the benefits of DFAM. As you move up the staircase, the value proposition shifts from the manufacturing process itself to the design improvements made by designers. Designers add the most value at the DFAM optimized level by significantly enhancing designs for 3D printing.
- 43. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 43 DFAM staircase
- 44. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 44 DFAM staircase
- 45. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 45 DFAM staircase
- 46. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 46 DFAM staircase
- 47. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 47 DFAM staircase
- 48. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 48 DFAM staircase
- 49. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 49 DFAM
- 50. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 50 DFAM
- 51. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 51 DFAM
- 52. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 52 DFAM
- 53. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 53 Components of Cost in AM
- 54. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 54 Components of Cost in AM
- 55. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 55 Components of Cost in AM
- 56. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 56 Nesting in AM
- 57. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 57
- 58. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 58
- 59. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 59
- 60. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 60
- 61. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 61
- 62. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 62
- 63. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 63
- 64. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 64
- 65. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 65
- 66. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 66
- 67. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 67
- 68. UNIT 4 Dr. Kiran Wakchaure ADDITIVE Manufacturing SANJIVANI COLLEGE OF ENGINEERING, KOPARGAON 68
- 69. Aircraft Oil Sump Housing Material: Titanium (Ti6Al4V) Size: Diameter of ~ 8” Height of ~ 10” Temp: 400 oC / 752 F 1. Using the rating scale on the DFAM scorecard, how strong a candidate is this part for additive manufacturing (enter overall total)? [5%] 3. What modifications would you make to the design of this part to improve its chances of success with additive manufacturing? [10%] 2. What is the best additive manufacturing process for this part, and why did you choose this process? [5%] 19 ± 5 Laser powder bed fusion Metal part, needs to withstand high temperatures, internal channels with significant detail Add generous fillets to make structure self-supporting Ensure internal channels are self-supporting, either by staying below 5mm, or changing shape to teardrop
- 70. Auto Engine Mount Bracket Material: Steel Size: 8” x 4” x 1” Temp: 100 oC / 212 F 1. Using the rating scale on the DFAM scorecard, how strong a candidate is this part for additive manufacturing (enter overall total)? [5%] 3. What modifications would you make to the design of this part to improve its chances of success with additive manufacturing? [10%] 2. What is the best additive manufacturing process for this part, and why did you choose this process? [5%] 18 ± 5 Laser powder bed fusion Load bearing, critical-to-function component. Laser powder bed fusion properties (post HIP and heat treatment) likely to meet requirements. Add cellular structures or use topology optimization to reduce mass, perform a stress analysis to validate performance Provide extra stock around mating locations to machine later for improved tolerances
- 71. Helicopter Shroud Cover Material: Titanium (Ti6Al4V) Size: 15” x 8” x 1” Temp: 100 oC / 212 F 1. Using the rating scale on the DFAM scorecard, how strong a candidate is this part for additive manufacturing (enter overall total)? [5%] 3. What modifications would you make to the design of this part to improve its chances of success with additive manufacturing? [10%] 2. What is the best additive manufacturing process for this part, and why did you choose this process? [5%] Switching this material to a polymer like ULTEM (PEI) and using Fused Deposition Modeling would work well since this is not a load-bearing component and temperature maximum is well within ULTEM specifications Add stiffening ribs, increase fillets around corners to mitigate stress concentration 19 ± 5
- 72. 1. Using the rating scale on the DFAM scorecard, how strong a candidate is this part for additive manufacturing (enter overall total)? [5%] 3. What modifications would you make to the design of this part to improve its chances of success with additive manufacturing? [10%] 2. What is the best additive manufacturing process for this part, and why did you choose this process? [5%] Aircraft Engine Stator Assemblies Material: Inconel 718 Size: Width:~9.9” Height: ~6” Temp: 350 oC / 662 F Laser powder bed fusion Metal part, needs to withstand high temperatures and failure critical rotary part. Geometry and surface finish of stator blades are important Add generous fillets around housing, machine mounting holes after print 21 ± 5
- 73. Aircraft bearing housing Material: Grey Cast Iron Size: Outer Diameter ~17” Inner Diameter 10” Temp: 200 C / 392 F 1. Using the rating scale on the DFAM scorecard, how strong a candidate is this part for additive manufacturing (enter overall total)? [5%] 3. What modifications would you make to the design of this part to improve its chances of success with additive manufacturing? [10%] 2. What is the best additive manufacturing process for this part, and why did you choose this process? [5%] 26 ± 5 Laser powder bed fusion (large size machine needed) Metal rotating part, likely failure critical. Mating surfaces and clearances of high importance, needs process with high resolution. Build this as an assembly of two components with stock material to machine to precise tolerances for bearing fit