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Lecture 13 Guidelines For Process Selection

This document discusses guidelines for selecting additive manufacturing (AM) processes. [1] It covers methods for selecting a process based on a part's requirements, capital investment needs, and production planning. [2] Key factors in process selection include material properties, speed, cost, and accuracy. [3] The document provides approaches to determine feasible material-machine combinations and make final selections based on technical and economic criteria.

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shanur begulaji
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471 views

Lecture 13 Guidelines For Process Selection

This document discusses guidelines for selecting additive manufacturing (AM) processes. [1] It covers methods for selecting a process based on a part's requirements, capital investment needs, and production planning. [2] Key factors in process selection include material properties, speed, cost, and accuracy. [3] The document provides approaches to determine feasible material-machine combinations and make final selections based on technical and economic criteria.

Uploaded by

shanur begulaji
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Chapter 13

The Impact of Low-Cost AM Systems /


Guidelines for Process Selection
Contents

1. Introduction
2. Selection Methods for a Part –
Quotation Support
3. Selection Methods for a Part –
Capital investment support
4. Challenges for Selection
5. Production planning and control -
Process planning support
6. Conclusion
7. Questions and Answers
1 . Introduction

Purpose of choosing AM process


1. Visual aids Constraint for selecting AM
2. Presentation models Process:
3. Functional models
4. Fit and assembly 1. Material properties
5. Patterns for prototype tooling 2. Speed
6. Patterns for metal castings 3. Cost
7. Tooling components 4. Accuracy
8. Direct digital/rapid manufacturing

Advantages of AM Process:

Time to market for complex


or customized
What we are going to learn today?

1. Quotation support
=== Given a part, machine and material selection.

2. Capital investment support


=== Given a design and industrial profile, machine selection?

3. Process planning support


=== Given a part and a machine, how do I set it up to work in the
most efficient manner alongside my other operations and existing
tasks?
2 . Selection Methods for a Part – Quotation Support

2.1 Decision Theory

1. Utility theory approach:


The best choice is the one that provides the highest utility (satisfaction) to the
decision maker.

• Three elements:

1. Options 2. Expectations
- Check the options (items) - Check the possible outcomes
- The items from which the for each option.
decision maker is selecting - Outcome – Time, cost, and
- Options = (A) = A1, A2, A3,…. surface finish, etc.
- Expectations = X = g(A)

3. Preferences
- how the decision maker
values each outcome?
- Utility (satisfaction)
functions on the
expectations
2. Decision Support Problem (DSP) technique:

• F. Mistree, J.K. Allen, and their co-workers have developed

• Considers multiple objectives and supporting human judgment.

• Mathematically modeling design decisions

• DSP facilitates several types of decisions:

1. Selection 2. Comprimise
- Selection of option from - The improvement of an
several alternatives alternative through
modification.

3. Coupled and hierarchical


There will be decision as
follow
1. Selection-Selection
2. Compromise- Compromise
3. Selection–compromise
2.2 Approaches to Determining Feasibility

Purpose of this = to get machine and material options

Deglin and Bernard Approach

• Evaluate a multi-criteria choice at a time.


• This is because people have no time to test and compare different solutions
• Tests are also money consuming and
• It is very difficult for someone to know all about industrial technologies
• Utilized a relational database system with extensive material, machine, and
application information.

National University of Singapore

• It identify feasible material/machine combinations, estimating manufacturing cost and


time, and determining optimal part orientations.
• Approach is similar to Deglin and Bernard approach.
• It utilized five databases:
• Three general databases = materials, machines, and applications and
• Two part-specific databases = geometric information and model specifications
Web-based AM selection systems

• Developed @ Helsinki University of Technology


• Through a series of questions, the selector acquires all technical information = part
accuracy, layer thickness, geometric features, material, and application requirements.
• The user specifies preferences for each requirement using a 5-element scale.
• The user receives a set of recommended AM machines that best satisfy their
requirements.

Preliminary Selection Decision Support Problem (PS-DSP)

• Ex. Fabricate metal lattice structures


2.3 Approaches to Selection

Purpose of this = to make final machine and material decision


3 . Selection Methods for a Part – Capital investment support

Purpose of this =
To select the AM machine to use for production of small custom orders.

• Consider the production of steel caster wheels.


• In previous selection process, there was only single dimension values for one
part.
• Now, parts are having a range of part dimensions.

• Requirement = Fast and low cost AM parts.


Step 1. Material = Stainless Steel Material

Step 2. Process Available =


1. Direct Metal Deposition
2. Direct Metal Laser Sintering
3. Electron Beam Melting
4. Laser Engineered Net Shaping
5. Selective Laser Melting, and
6. Selective Laser Sintering.

Step 3. What are the uncertainty Present?


• Caster wheels will be customized = a degree of geometric uncertainty involved.
• Check what features can customized = consider those the dimensions.
• With this information I get right machine to print the part.

Step 4. What are the required material properties?


1. Ultimate Tensile Strength (UTS)
2. Rockwell Hardness C
3. Density (Dens.)
4. Detail Capability (DC)
5. Geometric Complexity (GC)
6. Build Time (Time)
7. Part Cost (Cost)
Step 5 Get all the data to merit the process

• Scen 1 = geometric complexity > build time n part cost > UTS > Hardness > Density >
detailed features
• Scen 2 = All are equally important
• Proc 1 to 6 are different AM processes
Step 6 Get overall merit all processes

• Process 4 is the top ranking process in both scenarios.


• Second choice could be Process 2, 3, or 6, depending upon preferences.

Imp: It is a good idea to run additional scenario.


4 . Challenges for Selection

Different AM systems are focused on slightly different markets.

Large, expensive machines ==== Good accuracy and/or material properties,


abile to fine-tune the systems to meet specific needs

Cheaper systems ==== minimal setup and to produce parts of acceptable


quality in a predictable and reliable manner, less accuracy, less material
strength or flexibility of use.

The costs vs. the benefits so that user can choose the best machine to suit
their needs.

Solution ==
• Approaching a manufacturer or distributor of AM equipment to get the
information concerning the specification of their machine.
• But problem is that they are biased toward their own product and therefore
it is going to difficult to obtain true information.
We can also consider the following points:

1. The information in the system should be unbiased wherever possible.


2. The method/system should provide support and advice rather than just
a quantified result.
3. The method/system should provide an introduction to AM to equip the
user with background knowledge as well as advice on different AM
technologies.
4. A range of options should be given to the user in order to adjust
requirements and show how changes in requirements may affect the
decision.
5. The system should be linked to a comprehensive and up-to-date
database of AM machines.
6. Once the search process has completed, the system should give
guidance on where to look next for additional information.
Why we need to consider those points:

1. In SLS, for plastic parts printing, larger part printing is more efficient
that smaller parts. This is because it involves warm-up and cool down
time.

2. For FDM or SL parts, for plastic parts printing, smaller parts take less
printing time.

3. Beam deposition process is good for repairing mold and metal parts,
which is not possible (or very difficult) with the powder bed machine.

4. Thus, the decision can not be always straight forward.


5 . Production planning and control - Process

planning support
When a new part is presented to the SERVICE BUREAUS for building, in
general, the information presented to the process planner will include the
following:

1. Part geometry
2. Number of parts
3. Delivery date or schedule for batches of parts
4. Processes other than AM to be carried out (pre-processing and post-
processing)
5. Expectations of the user (accuracy, degree of finish, etc.)

Four topics will be explored further:

1. Production planning,
2. Pre-processing,
3. Part build, and
4. Post-processing.
1. Production Planning

1. Choose suitable AM process and AM machine. E.g. Selective Laser


Melting Process, EOS M290 machine
2. Check the machine availability --- check if machine is free for printing.
3. If batch printing is required, we can print all parts in one batch or
separate.
4. But, need to maintain repeatability of the properties.
5. Or else, potentially lengthy calibration builds may be needed.
2. Pre-Processing

• Change in dimensions of model


based of AM process
• Repair in STEP, IGES, or STl files
Modification of • Such as missing triangles,
the Design incorrectly oriented surfaces,
voids, etc.

• Very much specific to the AM


process and AM machine
• Setting up the process
Determination of parameters, e.g. Selective Laser
Melting: Laser Power, Scanning
Build Parameters Speed, layer thickness, etc.
• Process Simulation to successful
part printing.
3. Part Building – Printing Time and Part Orientation

3.1 Printing Time:

• It is a time required to print the parts.


• It is important to consider time required to print 1 part and many parts
together.
• For process like FDM and LENS – there is less difference in time required to
print 1 part and more parts.
• This is because here most of the time will spend the one layer.
• Height of the part should be less to reduce the printing time.

3.2 Part Orientation:

• Orientation of the part should be such that maximum number should be fit
in one batch while maintaining the properties of the part.
4. Post-Processing:

1. Part will compulsory required support removal.


2. Part may also required some kind of surface coating or preparation.
6 . Summary

1. Purpose of choosing AM process – Visual aid, presentation model,


functional model, fir and assembly, patterns for prototype, etc.

2. Quotation Support –

2.1 Decision Theory: Utility Theory Approach – based on the highest utility
(satisfaction) and Decision Support Problem – Gives several options
2.2 Get machine and material options
2.3 Select the machine and material

3. Capital Investment Support – Doing bench-marking

4. Challenges for Selection – gain knowledge of AM machine before


purchasing

5. Process Planning Support – Make plan, pre-process, part building, post-


process.
Thank You!

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