Advances in 3D Printing & Additive Manufacturing Technologies (eBook)

Professor David Ian Wimpenny is currently appointed as the Chief Technologist at the Manufacturing Technology Centre (MTC), Coventry, UK. He joined MTC in the year 2011 as a Technology Manager, and is working as a full time Technologist of the Component Technology Group at the MTC.  He is the member of Technology Strategy Board Panel. Prof. Wimpenny is a Funding Advisor of National Science Foundation (NSF) since 2006. He is the Chairman of the Additive Manufacturing & 3D Printing Forum for the HVM Catapult. His past roles include being head of the research at De Montfort University, Leicester, UK from 2009 to 2011 and director of Additive Manufacturing Technology Group in the Department of Engineering & Technology at De Montfort University from 2001 to 2011. Professor David Ian Wimpenny is also the member of the Additive Manufacturing Special Interest Group (AM-SIG) which was established by the Technology Strategy Board to develop a road map for the UK AM sector. He has served as an international reviewer for several international conference committees. His major activities are in the area of Additive Manufacturing, Rapid Product Development, Laser Printing, Surface Engineering and Manufacturing Production Tooling. He has published more than 60 papers in international/national journals and presented papers in seminars and international conferences. He has 3 patents to his credit and is involved with several major industries for Rapid Prototyping, Reverse Engineering and Computer Aided Design. He has guided 6 PhD students (awarded) and over 150 MSc students in his capacity as a professor. He is also a member of the review committees of several reputed international journals, including Additive Manufacturing, Rapid Prototyping and Materials Processing Technology. Professor David Ian Wimpenny has 2 books to his credit, Digital Model Production and Digital Design and Manufacturing in Dentistry. He was also a co-editor of the Rapid Prototyping Case Book.Dr. Pulak M. Pandey completed his B.Tech. degree from H.B.T.I. Kanpur in 1993 securing first position  and got Master’s degree from IIT Kanpur in 1995 in Manufacturing Science specialization. He served H.B.T.I. Kanpur as faculty member for approximately 8 years and also completed Ph.D. in the area of Additive Manufacturing/3D Printing from IIT Kanpur in 2003. He joined IIT Delhi as a faculty member in 2004 and is presently continuing as Associate Professor there. In IIT Delhi, Dr Pandey diversified his research areas in the field of micro and nano finishing, micro-deposition and also continued working in the area of 3D Printing (Selective Laser Sintering). He supervised 11 PhDs and more than 25 M.Tech theses in last 10 years and also filed 10 Indian patent applications. He has approximately 60 international journal papers and 35 international/national refereed conference papers to his credit. These papers have been cited for more than 1340 times with h-index as 20. He received Highly Commended Paper Award by Rapid Prototyping Journal for the paper “Experimental investigations into the effect of delay time on part strength in Selective Laser Sintering” presented in International Conference on Manufacturing Automation (ICMA 07)  held at National University  of Singapore during May 28-30, 2007. Many of his B.Tech. and M.Tech. supervised projects have been awarded by IIT Delhi. He is recipient of Outstanding Young Faculty Fellowship (IIT Delhi) sponsored by Kusuma Trust, Gibraltar and J.M. Mahajan outstanding teacher award of IIT Delhi. Dr Pandey is also an active reviewer of many leading international journals in the field of manufacturing science. He is an Editorial Board Member of the Rapid Product Development (RPD) Magazine endorsed by RP Society of India, French RP Association, Portuguese RP Association, Standard and Industrial Research Malaysia. Recently he has been invited as an editorial member of Mechanics of Advanced Materials and Modern Processes journal published by Springer. He is an active member of Additive Manufacturing Society of India. He was the team leader of one of the assessment teams for Academic Excellence Award 2009, UP Technical University, Lucknow. Recently, he led a delegation of 10 members to UK in the area of additive manufacturing and 3D Printing sponsored by British High Commission, India. During Additive Manufacturing Society of India's recent conference-AM 2015, Dr. P M Pandey has been awarded the award of appreciation as the leading researcher in additive manufacturing field in India.Mr. Jyothish Kumar is the Founder CEO of Rapitech Solutions Inc., Bangalore and also he is Founder President of Additive Manufacturing Society of India (AMSI), Bangalore. He gained his Bachelor of Engineering in Mechanical Engineering from The National Institute of Engineering, Mysore and Master’s degree in Rapid Product Development from De Montfort University, UK. Mr.Kumar is currently pursuing PhD research in Aerospace Applications of Additive Manufacturing Technologies. Prior to that Mr. Kumar has served in the mechanical engineering industry’s different disciplines such as Quality Assurance, Marketing, Sales and Product Development in India and abroad. He has specialized experience in Quality management Systems and Rapid Product Development which have been responsible in spearheading Rapitech Solutions Inc’s., efforts to streamline the business development operations for its customers. Mr. Jyothish Kumar brings credible experience and knowledge from his project work at RPMG, UK, association with other high scale (€9M) European Union funded projects with 33 other partners across Europe including Delcam Plc (UK), Materialise (Belgium) and Ducati (Italy), developing a new rapid prototyping process based on a combination of laser printing (electro photography) and Infrared sintering polymers. He holds Memorandum of Understanding (MOU) with international organization French Rapid Prototyping Association (APRF) & Central Manufacturing Research and Development Institute (CMRDI). Mr. Kumar is the Managing Editor of The Additive Manufacturing Technology Magazine (www.ammagazine.in), the only Magazine in India in 3D Printing & Additive Manufacturing Technologies. He was an Expert Speaker at 7th CII Annual Manufacturing Conference – Make in India: Rejuvenating Indian Manufacturing, 14-15 November 2014, Bangalore, India. He was a Keynote Speaker at 19th European Forum for Additive Manufacturing Technologies, 24-26 June, 2014, Paris, France. He has delivered expert talk at more than 20 engineering colleges in India and more than 12 Industries including defence and private organization. He has organized & guided as a convener for 1st, 2nd, 3rd, 4th & 5th International Conference on Additive Manufacturing Technologies and also convener for upcoming 6th International Conference on Additive Manufacturing Technologies which is scheduled to be held during 6-7th October, 2016 at Bangalore.

Preface 5
Acknowledgments 5
Contents 6
Editor and Contributors 8
1 Influence of Process Parameters on Tensile Strength of Additive Manufactured Polymer Parts Using Taguchi Method 13
Abstract 13
1 Introduction 13
2 Experimental Setup 14
2.1 Specimen Characteristics 14
2.2 Sintering Parameters 14
2.3 Equipment Characteristics 14
2.4 Design of Experiments 15
2.5 Experimental Procedure 16
3 Results and Discussion 16
4 Analysis of Results 17
4.1 Statistical Analysis 17
4.2 ANOVA 17
4.3 Response Graphs 18
5 Prediction of Optimum Performance 18
6 Conclusion 18
References 19
2 Determination and Comparison of the Anisotropic Strengths of Fused Deposition Modeling P400 ABS 20
Abstract 20
1 Introduction 20
2 Build Parameter Consideration 24
2.1 Layer Resolution 26
2.2 Model Interior 26
2.3 Support Fill 26
2.4 Color 26
3 Experimental Setup 27
3.1 Tensile Strength Test 27
3.2 Compressive Strength Test 27
3.3 Izod Impact Strength Test 28
3.4 Rockwell Hardness Test 28
4 Results 29
4.1 Tensile Test 29
4.2 Compressive Test 31
4.3 Izod Impact Test 33
4.4 Rockwell Hardness Test 35
5 Conclusion and Future Work 38
References 38
3 Estimation of the Effect of Process Parameters on Build Time and Model Material Volume for FDM Process Optimization by Response Surface Methodology and Grey Relational Analysis 40
Abstract 40
1 Introduction 41
2 RSM-Based Experimentation 42
3 Measurement of Responses 43
4 Grey Relational Analysis [10, 15, 16] 44
4.1 Data Preprocessing 44
4.2 Grey Relational Coefficient and Grey Relational Grade 45
4.3 Analysis and Discussion of Experimental Results 45
5 Results and Discussion 48
6 Conclusions 48
References 48
4 Current Trends of Additive Manufacturing in the Aerospace Industry 50
Abstract 50
1 Introduction 50
2 Background 51
2.1 Additive Manufacturing Application for the Aerospace Industry 51
2.1.1 GE Aviation—Leap Engine Fuel Nozzle Production Using Additive Manufacturing 51
2.1.2 SAFRAN R& D Employs Additive Manufacturing for Developing Engine Components and Aircrafts
2.1.3 NASA Creates Complex Rocket Injector Using Additive Manufacturing 53
2.1.4 Additively Manufactured Titanium Component in Airbus A350 XWB 54
2.1.5 Fused Deposition Modelling Reduces Tooling Cost and Lead-Time to Produce Composite Aerospace Parts 54
2.1.6 Boeing Using 3D Printing Technology 55
2.1.7 Lockheed Martin Space Systems Company Demonstrates Digital Production Innovations 55
2.1.8 Rolls-Royce 3D Prints Largest Component for Trent XWB-97 Engine 56
2.1.9 Pratt and Whitney Uses 3D Printing for Aero Engine Parts 56
2.1.10 Airbus Defence and Space Used Additive Manufacturing to Reduce Production Time of Satellite Parts 58
2.1.11 Hindustan Aeronautics Ltd., Used 3D Printing Technology for Aircraft Engine Model 58
2.1.12 Research and Development on Laser Metal Deposition Technology at Hindustan Aeronautics Ltd. (HAL) 59
2.1.13 Research and Development of Jet Engine at Monash University, Australia 60
2.1.14 Research on Additive Manufacturing of Ceramics for Direct Digital Investment Casting—Georgia Tech University, USA 61
2.1.15 The World’s First 3D Printed Aircraft—Southampton University Laser Aircraft 61
2.1.16 Development of New Material for Additive Manufacturing Aerospace Components—GKN Aerospace, UK 62
2.1.17 Additive Manufacturing Research in China—Aviation and Aerospace Applications 62
3 Summary 64
References 64
5 Influence of Oxygen Partial Pressure on Hydroxyapatite Coating of Additive Manufactured Component by Pulsed Laser Deposition 66
Abstract 66
1 Introduction 66
2 Experimental Details 68
2.1 Fabrication of Polyamide Substrate 68
2.2 Preparation of Hydroxyapatite Target for Deposition 68
2.3 Pulsed Laser Deposition 68
2.4 Film Characterization 69
3 Results and Discussion 69
3.1 Surface Microstructure 69
3.2 Surface Roughness 69
3.3 Crystallinity of HA Film 70
3.4 Growth Rate and Stoichiometry 71
4 Conclusion 74
References 74
6 Electro Discharge Machining of Ti-Alloy (Ti6Al4V) and 316L Stainless Steel and Optimization of Process Parameters by Grey Relational Analysis (GRA) Method 76
Abstract 76
1 Introduction 77
2 Experiment 78
2.1 Work Piece 78
2.2 Responses and Design of Experiment 79
3 Result and Discussion 81
3.1 Optimization Method 81
3.2 Grey Relational Analysis (GRA) Method 83
3.3 Calculation of Quality Loss, S/N Ratio and Scaled S/N Ratio 85
3.4 Determination of Process Performance Index (PPI) Values and Analysis of Variance (ANOVA) 85
3.4.1 Grey Relational Analysis (GRA) Method 85
3.4.2 Analysis of Variance (ANOVA) 85
4 Conclusion 87
References 88
7 Multi-objective Optimization of Mechanical Properties of Aluminium 7075-Based Hybrid Metal Matrix Composite Using Genetic Algorithm 90
Abstract 90
1 Introduction 90
2 Methodology 92
2.1 Mathematical Modelling 92
3 Experimental Details 94
3.1 Design of Experiments 94
3.2 Furnace and Moulds Used in Experimentation 95
3.3 Specimens Used in Impact Test, Hardness Test and Tensile Test 96
3.4 Experimental Data 96
3.5 Variation of Response Parameters with Respect to Variable Parameters 98
4 Formulation of Objective Functions of MOOP 99
5 Optimization of MOOP by NSGA-II 100
6 Results and Discussion 100
6.1 Single Best Compromise Pareto Solution 100
7 Conclusions 103
References 104
8 A Review on Status of Research in Metal Additive Manufacturing 105
Abstract 105
1 Introduction 105
2 Research on Design for Additive Manufacturing 106
3 Research on Effect of Process Parameters of Additive Manufacturing Routes in Metallic Components Manufacturing 107
4 Conclusion 109
References 109
9 Multi-response Optimization of Nd:YAG Laser for Micro-drilling of 304 Stainless Steel Using Grey Relational Analysis 111
Abstract 111
1 Introduction 111
2 Experimental 112
2.1 Material Selection 113
2.2 Laser Drilling Using Orthogonal Technique 113
2.3 Scheme for Measuring the Responses 114
3 Grey Relational Analysis 115
4 Result and Discussion 116
5 Analysis of Variance (ANOVA) 118
6 Conformation Test 119
7 Conclusion 119
References 120
10 Additive Manufacturing at French Space Agency with Industry Partnership 121
Abstract 121
1 Introduction 122
2 Context 122
3 Research and Development Activities 122
3.1 Realization, Dimensioning, Justification 123
3.2 Feasibility and Design 124
4 Examples of AM Parts 124
4.1 Injection Elements 124
4.2 Turbo-Pump Housing 126
4.3 Post-Processes and Controllability 127
4.4 Injector Fire Tests 129
5 Prospects 129
5.1 Design Challenges 129
5.2 Manufacturing Challenges 129
5.3 Challenges of Qualification and Validation 129
6 Conclusions 130
Reference 130
11 Wear Characterization of Direct Steel–H20 Specimens Produced by Additive Manufacturing Techniques 131
Abstract 131
1 Introduction 132
2 Description of Present Work 133
2.1 Machine and Process Parameters 133
2.2 Details of Machine 133
2.3 Process Parameters 134
2.4 Machining of Test Piece into Pin Samples 134
3 Results and Discussion 134
4 Conclusions 137
Acknowledgments 138
References 138
12 Rapid Manufacturing of Customized Surgical Cutting Guide for the Accurate Resection of Malignant Tumour in the Mandible 139
Abstract 139
1 Introduction 140
2 Materials and Methods 140
2.1 Case Report: Background 140
2.2 Radiology 141
2.3 Image Processing 141
2.4 VSP 141
2.5 CAD of CSCG 143
2.6 Manufacturing of CSCG 145
3 Testing of CSCG on Diseased Mandible 146
4 Discussion 147
5 Conclusion 148
References 148
13 Implant Analysis on the Lumbar-Sacrum Vertebrae Using Finite Element Method 149
Abstract 149
1 Introduction 150
2 Methods 151
2.1 Data Acquisition 151
2.2 3D Model of L5-S1 Vertebrae 152
2.3 Intervertebral Disc in 3-Matic 152
2.4 Implant Modelling 152
2.5 Finite Element Analysis 153
3 Results and Discussion 155
3.1 Analysis Without Placing the Screw 157
3.2 Analysis After Inserting the Implant 160
4 Conclusion 163
References 163
14 An Automated Acupressure Glove for Stress and Pain Relief Using 3D Printing 165
Abstract 165
1 Introduction 166
2 Literature Survey 167
2.1 Requirements to Overcome Current Challenges 168
2.2 Desirable Features 169
3 Project Idea 169
3.1 Mechanical Design 169
3.2 Medical Design 170
4 Design Methodology 170
4.1 The Glove 170
4.2 The Controller Unit 172
4.3 Integration 173
5 Results and Discussions 174
6 Conclusions 176
7 Future Scope 177
Acknowledgments 177
References 177
15 Development and Optimization of Dental Crown Using Rapid Prototyping Integrated with CAD 178
Abstract 178
1 Introduction 179
2 Methodology 179
3 CAD Model Development with 3D Scanner 180
4 CAD Model Development from DICOM Images 181
5 FEM Model Preparation with 3-Matic Software 182
6 Static Structural Analysis 182
7 Result and Discussion 184
8 Graphical Interpretations 187
9 Manufacturing of Dental Crown 188
10 Conclusion 189
11 Future Scopes 189
References 190
Index 192