Additive Manufacturing – Design Process and Application to Mechanical Engineering
Ahtiluoto, Matti (2019)
2019
Konetekniikka
Tekniikan ja luonnontieteiden tiedekunta - Faculty of Engineering and Natural Sciences
This publication is copyrighted. You may download, display and print it for Your own personal use. Commercial use is prohibited.
Hyväksymispäivämäärä
2019-01-09
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201812142860
https://urn.fi/URN:NBN:fi:tty-201812142860
Tiivistelmä
In the first part of the thesis, additive manufacturing technologies are studied. The most relevant technologies for mechanical engineering are recognized as SLM (Selective Laser Melting) for metals, HP Multi Jet Fusion and fused deposition modeling for polymers. Upcoming technologies such as Carbon3D digital light synthesis and Desktop Metal machines show promise for mass production.
In the second part, after analyzing the existing AM (Additive Manufacturing) technologies, literature review about design for corresponding technologies is conducted. Design for SLM is challenging and for this reason the focus is on SLM. Existing research simplifies the SLM process excessively and how design for SLM is approached. This often results in inaccurate conclusions. Also, lack of knowledge for design for SLM results in poor accuracy or build failures. For successful implementation of AM, it is crucial to consider the manufacturing method and its limitations from start to finish in design process. Printing orientation is among the most important factors in SLM.
In the third part, acquired design for AM knowledge and known design guidelines are applied to three case studies, in which parts are redesigned to be manufactured by SLM. Case studies include three different types of parts: first part with post-process machining, second part with internal channels and with the third part, topology optimization is utilized. During these case studies, more in-depth guidelines are developed to learn how to successfully design for AM. Successful design for AM means meeting financial and technical goals. Design process for different parts is developed and implementation of topology optimization is studied.
This thesis proposes a different and a practical approach on design for AM, as opposed to previous research. Emphasis is put on printing orientation and on understanding the SLM design process as a whole.
In the second part, after analyzing the existing AM (Additive Manufacturing) technologies, literature review about design for corresponding technologies is conducted. Design for SLM is challenging and for this reason the focus is on SLM. Existing research simplifies the SLM process excessively and how design for SLM is approached. This often results in inaccurate conclusions. Also, lack of knowledge for design for SLM results in poor accuracy or build failures. For successful implementation of AM, it is crucial to consider the manufacturing method and its limitations from start to finish in design process. Printing orientation is among the most important factors in SLM.
In the third part, acquired design for AM knowledge and known design guidelines are applied to three case studies, in which parts are redesigned to be manufactured by SLM. Case studies include three different types of parts: first part with post-process machining, second part with internal channels and with the third part, topology optimization is utilized. During these case studies, more in-depth guidelines are developed to learn how to successfully design for AM. Successful design for AM means meeting financial and technical goals. Design process for different parts is developed and implementation of topology optimization is studied.
This thesis proposes a different and a practical approach on design for AM, as opposed to previous research. Emphasis is put on printing orientation and on understanding the SLM design process as a whole.