Lecture 13.pptx forming.................

Forming

1. Computer Applications in Engineering By/ Dr Ahmed Ibrahim E-mail: [email protected] Tel: [phone] Minia University Faculty of Engineering Prod. Eng.& Mechanical Design Dept. (Lecture 10)

2. Additive Manufacturing and Rapid Prototype. Learning Objectives

3. What is Additive Manufacturing Process of joining materials to make objects from a 3D model Different processes Different modeling techniques/capabilities Different end-uses Different from traditional manufacturing (subtractive process) Injection molding CNC Machining Plastic Forming/Joining

4. Traditional (subtractive) Manufacturing: Top Down Additive Manufacturing Bottom Up (literally)

5. Used for Fabrication Rapid Prototyping Direct Part Production Useful when Object needed does not exist Object needed is heavily customized Object needed is difficult to obtain Used by Airlines, Healthcare, Military (and many more)

6. Types of Additive Manufacturing Stereolithography Focused UV light Transform liquid photopolymers into solid form Layer-by-layer production Selective Laser Sintering (SLS) Laser emitting infrared radiation Fuses (sinters) powder material Polymers, metals, ceramics, foundry sand, etc. Layer-by-layer production

7. Laser Cladding Powder sprayed through nozzle into laser Layer-by-layer production Can create very dense, homogeneous structures Laminated Object Modeling (LOM) Stack thin, pre-cut sheets Layer-by-layer production One of the earliest forms of Additive Manufacturing

8. Fused Deposition Modeling (FDM) Stream of hot, viscous material (thin thermoplastics) Layer-by-layer production Filament is melted, deposited and then hardens Inkjet Printing (IJP) Micro-particle binder material Powder bed Micro-particles joined to powder Layer-by-layer production

9. Laser Metal Deposition (LMD) Metal powder melted using laser Forms a metallurgical bond Shares elements: Stereolithography and Laser Cladding Capable of processing complex metals Layer-by-layer production

10. 1. Selective laser sintering (SLS) additive technique layer of powder placed on base high power laser used to fuse selected parts of the powder the powder bed is lowered a small amount and a new layer of powder is spread does not require any support structures

11. 2. Fused deposition modeling (FDM) additive technique material is laid down in layers plastic material is melted in a nozzle that moves in XY direction typically uses ABS plastic support material is required

12. 3. Stereolithography (SLA) additive process uses a vat of liquid UV-curable resin and a UV laser exposure to the laser causes the material to harden after a pattern has been traced, the platform descends and a resin filled blade recoats the top requires support structures 15

13. 4. Laminated object manufacturing (LOM) sheet is adhered to substrate with a heated roller laser traces out the outline of the layer non-part areas are cross- hatched to facilitate removal of waste material next layer is pulled across and the process is repeated

14. cutting, stacking, and bonding successive layers of paper

15. 5. Electron beam melting (EBM) metal parts are made from a metal powder a layer of powder is spread, and the part region is melted together by a computer-controlled electron beam

16. 5. 3D printing (3DP) “inkjet” type process a fine powder of plaster or corn starch is bonded by “printing” an adhesive from the printhead considered the fastest technique

17. Materials for Additive Manufacturing Plastic Fused Deposition Modeling

18. Sands and Powders Laser Sintering and Inkjet Printing

19. Others Ceramics, Food, Skin 27

20. APPLICATIONS Biomedical Engineering: Creating limbs and other body parts out of metal or other materials to replace lost or damaged limbs. More accurate Faster

21. Construction and Architecture 3D printing concept to create entire buildings

22. Product Prototyping Allows designers to create and the next day see and touch their design Earlier the process was tedious without 3D printing

23. All Questions Are Warmly Welcome