Beruflich Dokumente
Kultur Dokumente
Mahendrakumar Ramamoorthy, Department of Industrial and systems engineering, The State University of New York at Buffalo, Buffalo, United States of America mramamoo@buffalo.edu December 2013
Abstract:
Today the industrial sector is highly competitive and increasingly companies are attaching greater importance to the need to differentiate their product and service offerings in order to remain profitable. Typically, firms are adding new technologies to their products to differentiate, forming alliances with their customers, adding service features to their manufactured product offerings, reducing time to market for new products, reducing the number of suppliers and forming longerterm relationships and alliances with those that remain, expanding their product range, and reducing their cost base to become the lowest cost producer. Rapid prototyping technologies have the potential to contribute something to the achievement of most, if not all these actions. Though Rapid Prototyping Techniques find vast areas of application, we confine our paper only within aerospace sector. This review paper deals with different types of Rapid Prototyping methods used particularly in aerospace industry, their advantages and limitations. The scope of this paper is extended to their current achievements and future of RP in aerospace sector.
Keywords: Rapid Prototyping, Stereo lithography, Selective Laser sintering, 3D printing, Fused Deposit Modelling, Laminated Object Manufacturing
1. Introduction:
The nature of the aerospace industry demand that all parts are as reliable as they possibly can be. No corners can be cut when it comes to the design and manufacture of aerospace parts which is why the best processes available need to be implemented. The complexities involved with aerospace design make additive manufacturing the obvious choice as other forms of machining simply cannot meet the required standards. Rapid prototyping has emerged as a key enabling technology with its ability to shorten product development and manufacturing process that produces a physical prototype from a 3D cad model layer by layer which is also called as layer manufacturing.
It aims to produce prototype relatively quickly for visual inspection, ergonomic evaluation, and form fit analysis and as master pattern for product. The application of R.P to the product manufacturing process has shown a 60% decrease in lead time over traditional method with the various advantages that R.P technology promise R.P has begun to make its way in to the aeronautical industry and is set to have profound implication. The Northron Grunman global hawk, it is just one of many vehicles which depend on R.P for its development. Some of the desirable features which fits the RP into aerospace sector are its capability to test new materials, ability to build geometrically complex structures, and elimination of higher tool cost of low volume production. Here we will discuss the different types of RP techniques available in market and its achievements.
The professional literature in RP contains different ways of classifying RP processes. Liquid-based RP systems the initial form of material is in liquid state and, by a curing process, the liquid is converted into solid state; the system includes: 3D Systems Stereo lithography (SLA), Light Sculpting, Rapid Freeze and Two Laser Beams; solid-based RP systems the initial form of material is in solid state, except for powders (wire, roll, laminates, pellets); this system includes: Stratasys Fused Deposition Modeling (FDM), 3D Systems, Multi-Jet Modeling System (MJM) and Pares lamination Technology (PLT);
Powder-based RP systems the initial form of material is powder; the system includes: 3D Systems Selective Laser Sintering (SLA), Precision Optical Manufacturings Direct Metal Deposition (DMD) and Z Corporations Three Dimensional Printing (3DP). However, one representation based on German standard of production processes classifies RP processes according to state of aggregation of their original material and is given below.
1. 2. 3. 4. 5.
Stereo Lithography (SLA) Selective Laser Sintering (SLS) Fused deposition modelling (FDM) Laminated Object Manufacturing(LOM) Three Dimensional Printing(3DP)
Here we will discuss briefly about each techniques process, their advantages and also the limitations.
3.1.
The Most accurate machine available among all other RP technique and the first commercially accepted RP process is the Stereo Lithography. It was invented by Charles Hull in 1987 who worked for 3D systems. This additive process is based on selective polymerization of a photosensitive liquid resin using ultraviolet light. The process begins with by filling a vat with liquid photo curable resin acryl-ate and placing it in the elevator table. A UV Helium-Cadmium or argon laser beam then traces a single layer cross section onto the surface of a vat of liquid polymer. Due to the absorption and scattering of beam, the reaction only takes place near the surface and voxels of solid polymeric resin are formed. The photo polymerization Process happens (linking small molecules known as monomers into chain-like larger molecules known as polymers) which causes the polymer to harden precisely at the point where the ultraviolet light hits the surface. The Beam is positioned and moved in horizontal X and Y directions of the pre-defined boundary and it is controlled by a galvanometer driven mirrors. The laser scans the first layer and platform is then lowered equal to one slice thickness (typically 0.05 mm to 0.15 mm (0.002" to 0.006")) and left for short time (dip-delay) so that liquid polymer settles to a flat and even surface and inhibit bubble formation. Then, a resin-filled blade sweeps across the part cross section which recoats it with fresh material. On this new liquid surface, the subsequent layer pattern is traced; adhering to the previous layer, in this way, the model is built layer by layer from bottom to top. When all layers are completed, the prototype is about 95% cured. Once the complete part is deposited, it is removed from the vat and then excess resin is drained. It may take long time due to high viscosity of liquid resin. The green part is then post-cured in an UV oven after removing support structures.
Advantages:
Stereo lithography is the ideal choice for Form and Fit testing of new designs, Functional parts for special projects , Architectural models and one-offs, Form and Fit testing of new designs ,Testing of new designs or reverse engineered parts, Investment Casting patterns for Quick Turn cast metal parts ,Limited run production parts. Achieving High accuracy in industrial standard. Bluestone parts resist deformation even under heavy loads and Resists temperatures up to 250C, making it suitable for tooling or other demanding applications. Suitable for thin-walled parts that require the stiffness of high performance engineering parts Improves/enhance demanding applications: wind tunnel, soft tooling and injection mold tooling. Consistent mechanical properties, even on long builds Good Surface Finish
7
Limitations:
Support structures always needed. Removal of support structures can be difficult. Requires post-curing. Limited materials (Photo polymers). Some war page, shrinkage and curl due to phase change.
3.2.
Selective Laser Sintering (SLS) was developed and patented by Dr. Carl Deckard and academic adviser, Dr. Joe Beaman at the University of Texas at Austin in the mid-1980s, under sponsorship of DARPA. It serves as an alternative additive manufacturing process for the liquid curing system. SLS uses a high power laser beam (for example, carbon dioxide laser) to sinter successive layers of powder spread on a layer instead of liquid. The powder is metered in precise amounts and is spread by a counter-rotating roller on the table. A laser beam is used to fuse the powder (by preheating the powder to a temperature just below its melting point) within the section boundary through a cross-hatching motion. The table is lowered through a distance corresponding to the layer thickness (usually 0.01 mm) before the roller spreads the next layer of powder on the previously built layer. The un-sintered powder serves as the support for overhanging portions, if any in the subsequent layers.
Advantages:
Selective Laser Sintering (SLS) is the ideal choice for Prototypes that require material properties that closely replicate injection-molded parts. Depending on the material, up to 100% density can be achieved with material properties comparable to those from conventional manufacturing methods. The main advantage is that the fabricated prototypes are porous (typically 60% of the density of molded parts), thus impairing their strength and surface finish. No post curing required. Variety of materials. Mechanical properties of Nylon & Polycarbonate parts are used and hence Excel in load bearing applications at higher temperatures. Fast build times. Eliminate painting by using black color. Unlike some other additive manufacturing processes SLS does not require support structures due to the fact that the part being constructed is surrounded by un-sintered powder at all times, this allows for the construction of previously impossible geometries. Compatible with autoclaves, low-temperature furnaces, and vacuum plaster casting methods.
Limitations:
Rough surface finish. Mechanical properties below those achieved in injection molding process for same material. Material changeover difficult compared to FDM & SLA. Many build variables, complex operation.
3.3.
Another famous additive manufacturing technology in market is Fused Deposition Modelling (FDM).It was developed by S. Scott Crump in the late 1980s and this process was first commercialized by Stratasys in 1990. The FDM machine use a CAD model to produce a physical prototypes by taking the STL file created by the CAD model and first converting it into an SML file which generate a tool-path to maneuver for each layer or slice to deposit material. The slice thickness can be set manually to anywhere between 0.172 to 0.356 mm (0.005 to 0.014 in) depending on the needs of the models. The fused deposition modelling (FDM) process creates parts by extruding material (normally a thermoplastic polymer, ABS - engineering and medical grade - plastic, Polycarbonate and investment casting wax) in a cross-hatching fashion. The Machine consist of a heating chamber which is a 90-degree curved elbow wrapped in a heating element, which serves as a melting area for the material and to change the direction of the filament flow so that material is extruded vertically downward. The head is moved in the horizontal X and Y directions for producing each layer through zigzag movements. The material solidifies in 0.1s as it is directed on to the workplace. Once a layer is complete the supporting table is moved in the Z Direction for building the next layer. The FDM process does not need support to produce part in most cases as head forms a precision horizontal support in mid-air as it solidifies. But for overhanging parts, a support may still be required, which can be manual or, water soluble supports to reduce part distortion.
10
Advantages:
No post curing. Variety of materials. Easy material changeover. Office environment friendly. Low end, economical machines. The advantage of FDM is the material capacity to handle heat and other demanding product tests. It is a feasible option for both rapid prototyping and rapid manufacturing, producing parts that are both accurate and durable. It is able to fabricate fully functional parts that have 85% of the strength of the actual molded part, because of this reason it is highly applicable for Aerospace and Aviation industries.
Limitations:
Not good for small features, details and thin walls. Surface finish. Supports required on some materials / geometries. Support design / integration / removal is difficult. Weak Z-axis. Slow on large / dense parts.
11
3.4.
The first commercial Laminated Object Manufacturing (LOM) system was developed by Helisys of Torrance, CA in 1991. A manufacturing process that uses a carbon-dioxide laser to create successive cross-sections of a three-dimensional object from layers of paper with a polyethylene coating on the backside. The first step is to create a base on which the paper can attach itself to. This is done by placing a special tape down onto the platform. A sheet of paper is fed through with the aid of small rollers. As the paper is fed through, a heated roller is used to melt the coating on the paper so that each new layer will adhere to the previous layer. The carbondioxide laser then cuts the outline of the cross-sectional pattern into the top layer of paper. Once the laser is done cutting the pattern, it creates a border around the build that contains the desired part. This enables the part to stay intact as each new layer is created. Once the border has been cut, the laser then proceeds to create hatch marks, or cubes that surround the pattern within the border. The cubes behave as supports for the part to ensure that no shifting or movement takes place during the entire build. When the build is completed, the part, attached to the platform, needs to be removed from the LOM. Depending on the size of the part, the block to be removed may take more than one person to remove the build from the LOM. After the part has been successfully removed from the LOM, it must then be removed for the actual platform. Again this may take the work of more than one individual. A wire is used and placed between the part and the platform to "cut" the part away from the metal platform. The border, or frame of the part is then removed. The next step involves removing the supports. Often times the supports can be removed from simple shaking the part; other times it is necessary to use a chisel to pry the cubes away from the part. When all of the cubes have been removed, the unfinished part is sanded down and a lacquer is used to seal the part. Being that LOM parts are made for paper, humidity and temperature affect the structure and composure of the part if it is not coated; hence, the lacquer serves as a protective measure. The LOM is very useful in manufacturing large parts quickly.
12
Advantages:
Speed--The LOM process does not convert liquid polymers to solid plastics nor does it convert plastic powders into sintered objects, but instead it uses existing solid sheet materials which are glued using a hot roller and cut with a laser beam. Unlike competitive technologies such as Stereo lithography and Selective Laser Sintering, the laser in the LOM process does not have to scan the entire surface area of each crosssection, rather it only has to outline its periphery. Therefore, parts with thick walls are produced just as fast as those with thin walls. The LOM process is especially advantageous for production of large and bulky parts which are often encountered in the aerospace and automotive industries. The reason for this unique advantage is the fact that the core manufacturing material does not need to be formed since the laser merely determines the geometrical shape by removing excess material. Simplicity--The simplicity of the LOM process and systems allow them to be practical extensions to many manufacturing and design environments. LOM machines can be thought of as peripheral devices to a CAD workstation, allowing any designer to output any design directly to an LOM system. The need to create additional support structures is completely eliminated with the process; something which is essential for competitive stereo lithography systems. The LOM process is quite straightforward and the user does not need to have any specific knowledge of chemistry, physics, mechanics or electronics in order to operate the machine.
13
The systems are designed using standard electromechanical components which makes them easy to maintain and troubleshoot.
Limitations:
Need for decubing, which requires a lot of labor Emission of smoke or fumes Can be a fire hazard Finish, accuracy and stability of paper objects not as good as materials used with other RP methods
3.5.
Three Dimensional Printing (3DP) technology was developed at the Massachusetts Institute of Technology and licensed to several corporations. The process is similar to the Selective Laser Sintering (SLS) process, but instead of using a laser to sinter the material, an ink-jet printing head deposits a liquid adhesive that binds the material. The 3D printing process begins with the powder supply being raised by a piston and a leveling roller distributing a thin layer of powder to the top of the build chamber. A multi-channel ink-jet print head then deposits a liquid adhesive to targeted regions of the powder bed. These regions of powder are bonded together by the adhesive and form one layer of the part. The remaining free standing powder supports the part during the build. After a layer is built, the build platform is lowered and a new layer of powder added, leveled, and the printing repeated. After the part is completed, the loose supporting powder can be brushed away and the part removed. 3D printed parts are typically infiltrated with a sealant to improve strength and surface finish.
14
Advantages:
Cost effective solution for small to medium size parts in shortest lead time Parts have little flexibility, makes them suitable for limited snap features or thin wall flexible features Environmental exposure do not alter the size of the part or its features. Ideal for general purpose parts exposed to temperature, water and many chemicals. High level of finish can be achieved by sanding and other post processing techniques. These parts can be further machined, polished or painted.
Limitations:
3DP parts have a ribbed and little rough appearance due to layering beads of plastic. Not suitable for extensive functional testing Could be a slow process for large build volume parts.
15
Property Method SLA (SL5170) SLS (Protoform ) FDM (ABS) Materials Used
Hardne ss(Shor e D) 85
Polymer 8700 Ceramic, Wax and Alloy 7100 Wax and Polymer 5000
408 360
6 50
_ 9500
625 380
1.25 2
_ 105
16
Similar achievements is the wind tunnel model of the European tilt rotor realized by the Rapid Prototyping Department of CRP Technology during the first months of the 2007. Wind tunnel Testing is one of the major part in the engine rotor design in any aerospace sector and this achievement helped the industry in realizing the worthiness of RP. It proved that the RP models can withstand in high profile testing environment. The wind tunnel model of the European tilt rotor realized by the RP department of CRP technology by using wind form material. The model was completed and tested in a very short interval of time with excellent result and high performing mechanical and aerodynamic properties. Thus Layer-build technology is successfully implemented for a low rate production application and early design criteria .The benefits, which included design flexibility, no tooling and just-in-time delivery, all contributed to the end customer accepting and allowing this technology to be implemented in aerospace industry.
17
The very first limitation of RP in Aerospace industry is the lack of an appropriate range of materials for its application. This made authorities to impose very stringent quality measures for the usage of materials in real time parts manufacturing in aerospace industry. Currently low volume application products are produced with acceptable materials like epoxy resin, composite materials and sintered nylon and those products are often good enough for Evaluation of components by visualization Evaluation of design variations Estimation of the surface quality of the aircraft model Evaluation of the aircraft interior Ergonomic valuation with the aid of virtual reality.
Materials like flame retardant nylon, exotic metal such as titanium and high order engineering grade materials are under R&D and they can innovate the future of R.P in Aerospace industry. All vehicle programmes manned, unmanned, civil and military could benefit from rapid prototyping. All system builders large and small - can use rapid prototyping to reduce their exposure to risk considerably.
18
7. Conclusion:
Rapid Prototyping is proving to be a successful method starting from early design phase to the final part manufacturing in aerospace industry. Cost savings and model design/fabrication time reductions greater than a factor of 4 have been realized for RP techniques as compared to current standard model design/fabrication practices. Compared to its metal counterparts RP products are short of strength and accuracy. But still they can be accepted in the preliminary stages of design where full metal fabrication and machining processes consumes lot of money and time. Scaled down model of the components and their final assembly with lesser accuracy are acceptable for the initial design testing. The use of RP models will provide a rapid capability in the determination of the aerodynamic characteristics of preliminary designs over a large Mach range. This range covers the transonic regime, a regime in which analytical and empirical capabilities sometimes fall short. However the industry with very high standard for safety and place for no deviations like the aerospace sector cannot replace the proved machining processes or metal parts with the rapid prototyping. Considerable research over the new kind of materials for fabrication and increasing the capacity like size and strength of the current RP models can lead the aerospace sector into greater heights.
8. Reference:
1. Advancement of rapid prototyping in aerospace industry -a review Vineet Kumar vashistha, Rahul Makade, neeraj Mehla, Department of Mechanical Engineering, NIT,Hmaripur, India. 2. Rapid Prototyping Industrial Analysis, Trevor Boehm, Maria-Isabel Carnasciali , M. Elizabeth Douglas, Marco Gero Fernandez ,Christopher Williams 3. Rapid prototyping technologies, applications and part deposition planning Pulak M. Pandey, Department of Mechanical Engineering, IIT,Delhi, India. 4. "Rapid Prototyping is Coming of Age," Steven Ashley, Mechanical Engineering, vol. 117, no. 7, July 1995, pp. 62-68. 5. Wikipedia.org 6. http://www.hk3dprinting.co.uk/aerospace-rapid-prototyping.html 7. http://www.proto3000.com
19