Advanced Manufacturing Systems Assignment 1

Name Student Number Faculty Department

Farai Chitambara N005 1104F Industrial Technology Industrial and Manufacturing Engineering Department

Supervisor Course

Dr. Z.B.Dlodlo Advanced Manufacturing Systems

Question 1 a) Rapid Prototyping (RP): is a term most commonly used to describe a variety of processes, which are aimed at quickly creating three-dimensional physical parts from virtual 3D computer models using automated machines. The parts are built directly from the 3D CAD model and can match that model very closely (within the precision limits of the chosen process).Rapid prototyping is different from traditional fabrication. Rapid manufacturing is an additive fabrication technique for manufacturing solid objects by the sequential delivery of energy and/or material to specified points in space to produce that part. Current practice is to control the manufacturing process by computer using a mathematical model created with the aid of a computer. Rapid manufacturing done in parallel batch production can provide a large advantage in speed and cost compared to alternative manufacturing techniques such as plastic injection molding or die casting. Rapid manufacturing may involve custom parts, replacement parts, short run production, or series production. (When the part is used in the development process only, the appropriate term is rapid prototyping.)

1 b) i) Five steps in a general RP system: 1. 3D Modeling this is the stage where a 3-Dimensional model is created in Computer Aided Drawing software and the equipment needed at this stage is a 3D workstation. An important aspect in this stage is that RP systems require a closed volume of the model whether the basic models are surfaces or solids. 2. Data conversion and transmission- the RP machines are conversant with .STL format which represent their geometries in the form of polygons therefore the CAD model has to be converted to.STL format. Highly curves surfaces require more polygons therefore the files for curved surfaces are very large. The conversion step is the simplest but with the low speed of a PC a complex models can take several hours instead of a few minutes. Most CAD vendors supply the CAD/STL interface. The transmission step is used for the transference of the residue files on the PC to the RP system. Data transmission via agreed formats such as IGES or .STL can be done through diskettes, e-mail and LAN networks. 3. Checking and preparing- The model is checked for errors and returned for correction. The material required and other specifics are detailed in this stage.

4. Building-This is the use of rapid manufacturing technologies like SLA, SGC and 3D Modeling to build the model or part. 5. Post-processing after the building process the model that has been built is not usually in its perfect or required state therefore further processing is required. This stage includes process like cleaning, post-curing and finishing (milling, polishing and others). After this stage the prototype is ready for presentation, testing, engineering analysis or what ever activity for which it is built.

ii) Steps 3, 4 are iterated because stage 3 involves correcting the model for errors. Stage 4 involves building the model and it is often necessary to carry out repeated runs until the required model as been obtained

Question 2: Basic differences between NC programming and Rapid Prototyping in terms of the CAD Model

The Rapid Prototyping process requires that the CAD model be converted into an STL format to be produced however this stage is not relevant in NC programming where a program of the CAD model is written. The STL model produced for the RP process is made up of triangles/polygons which are not considered in the CAD model for NC programming. The model is required in 3D format for building in Rapid Prototyping but in NC programming the model can be extracted in 3D or in numeral and word written programs. In NC programming the CAD model goes through a post-processer where it is converted into Machine Control Data, a data format which is usable with NC machines, Rapid prototyping on the other hand converts the CAD model to SLT format. NC programming obtains tool path information directly from the 3D CAD model so as to direct the movement of the tool whilst in Rapid Prototyping the CAD model is first sliced to thin sheets (This is 2D format) from which the path of the tool is obtained

b) Cleaning is the removal of residue building material from the built model for example removing wax from the SGC created model and washing of the unsolidified resin from a Stereolithography model. Post-curing this is the process of completing the curing process which may not have been completed by exposure through the laser or UV lamp during the layer by layer exposure of the prototype.

Finishing this is post-processing the built prototype through operations like sanding, painting, polishing, drilling, milling, sealing with resin so as to give the prototype the functions and appearance its supposed to have to serve its function.

RP systems that do not require post-curing: Laminated Object Manufacturing Solid Ground Curing

RP systems that do not require cleaning Fused deposition modelling

Question 3 a) Stereolithography apparatus (SLA) SLA creates 3D plastic objects directly from CAD data Process begins with vat filled with the photo curable liquid resin and the elevated table set just below the surfaces of liquid resin. Operator loads 3D CAD data to the system and supports designed to stabilize the part during building. Translator converts CAD data to into STL file. The computer controlled optical scanning sys then directs and focuses the laser so that it solidifies a 2D cross section corresponding to the slice. Elevator table then drops enough to cover the solid polymer with another layer of the liquid resin. The process continues until the object is fully built. Solid ground curing SGC Cross sections of the CAD model to be built are prepared and cross sections are generated digitally and transferred to the mask generator. Data is placed mask plate is charged through an image wise ionographic process. The charged image is then developed with electrostatic toner. Thin layer of photopolymer resin is spread on the work surface. Photo mask from mask generator is placed above work piece and aligned under a UV lamp. UV lamp is turned on for a few minutes instantly curing the polymer curing it to harden. Resin which has not solidified is sucked out by vacuum pump .melted wax is spread onto the cavities created after

collection of resin.wax cooled and milled to produce a even layer process repeats continuously creating a model layer by layer. Both of these processes build the object layer by layer to create the model using the CAD file converted to STL file format. b) Advantages of SLA are; Round the clock operation unattended Good surface finish Can build volumes Good accuracy Good user support Wide range of materials

Disadvantages of SLA are Requires support structures Requires post processing

Requires post curing

Advantages of SGC are; No post curing Process is self supporting Minimum shrinkage No hazardous odors generated

Disadvantage of SGC are; Requires large space Wax gets tuck on the corners Waste material generated Noisy

c) One laser beam is assumed to not fully cure the photo polymer but two photons will provide sufficient energy to cure the photo polymer so two sources of laser beams are provided from two sides and create the 3d model from the CAD system. In this method of curing the two laser cannot cure the substrate individually they support each other to cure the substrate.

Question 4 a) Reasons for developing Non-Traditional Machining techniques Non-traditional machining techniques were developed This was in response to increasing demands in industry for better, more consistent work-piece quality and higher production efficiency in the processing of hard, tough materials, work-pieces with unusual finishing requirements and parts with complex shapes that require processing beyond the normal capabilities of traditional machining processes. The other reason fro the development of these techniques is to increase the ease of production. The cost factors were also critical in the development of these machining processes since cost reduction is a major factor in profit-making. The development of new material which were harder and made demands that traditional machining processes could not meet also led to the development of these non-traditional machining methods. Technological development is a major feature of manufacturing industries and the scientific world this therefore was another push factor to the development of non-traditional machining methods

a) b) The non traditional machining techniques were introduced in the 1940s.

Question 5

a i) Electrochemical Machining Electrochemical Grinding ii) Electrochemical Machining

This process utilizes electrolysis for machining. As illustrated in the diagram above the workpiece is made the anode whilst the tool is made the cathode in an electrolyte medium which is continuously pumped between the tool and the container housing the work piece. The DC current is passed and the work-piece material which is the anode is depleted towards the tool which is the cathode however the work-piece material is prevented from deposition on the cathode (tool) and flushed away by the flow of the electrolyte.

Electrochemical Grinding The same electrolysis process that is utilised in Electrochemical Machining is utilised in Electrochemical grinding to enhance the abrasive grinding process. The grinding wheel even in this case utilises the abrasive diamond grains and their life is increased by this electromechanical addition. Electrolyte is supplied into the gap that is created by the

diamond grains separating the body of the wheel and the ground surface as shown .The grains also remove an electrically resistant film from the surface of the work-piece. In the carbide grinding operation savings are quoted of 90% of the wheel cost and 50% of labour cost. In general the process is applied to hard materials, including hardened steel.

a) Four other families of non-traditional processes are: Electrical Discharge Processes Thermo-Electric Processes Mechanical Processes Chemical Processes

b) Listing of the two corresponding process under the families above. i. Electrical Discharge Processes Electrical Discharge Machining Electrical Discharge Wire Machining

ii.

Thermo-Electric Processes Plasma Arc Machining Laser Beam Machining

iii.

Mechanical Processes Ultrasonic Machining Abrasive Flow Machining

Question 6

a) b)

LASER - Light Amplification by Stimulated Emission of Radiation Excimer Laser

An excimer laser; - a form of ultraviolet laser which is commonly used in eye surgery and semiconductor manufacturing. The excimer is an acronym for 'excited dimer. An excimer laser typically uses a combination of an inert gas (argon, krypton,

or xenon) and a reactive gas (fluorine or chlorine). Under the appropriate conditions of electrical stimulation, a pseudo-molecule called an excimeris created, which can only exist in an energized state and can give rise to laser light in the ultraviolet range. The UV light from an excimer laser is well absorbed by biological matter and organic compounds. Rather than burning or cutting material, the excimer laser adds enough energy to disrupt the molecular bonds of the surface tissue, which effectively disintegrates into the air in a tightly controlled manner through ablation rather than burning. Thus excimer lasers have the useful property that they can remove exceptionally fine layers of surface material with almost no heating or change to the remainder of the material which is left intact. These properties make excimer lasers well suited to precision micromachining organic material (including certain polymers and plastics)

c)

Two other types of lasers are the Nd: YAG laser and the Carbon dioxide laser.