Machine Tools And Devices For Special Technologies

Rapid Prototyping

Slovak University of TechnologyFaculty of Material Science and Technology in Trnava

Rapid prototyping

Based on the creating and using of virtual space numerical model of the designed product.

Possibility of straight production of the designed product model eventually of final product on the base of 3D data transport from CAD system to Rapid Prototyping system.

Prototype

First material visualisation of the workpiece and it is for the next processing of workpiece design necessary.

Gets:Practical information about function, quality of

product and about costs for his producing.

Prototyping We can divided it into several groups: Mock – up – prototype gives to user the view how it approximately

look, Bread-board – prototype is using but yet has not created users

border line, Scale model – has users border line but supported only parts of all

conditions, Concept – car – where the prototype is generated to assignment of

market price, Simulation – where the prototype extracts screenplay and

conception of user, Characteristic model – formally specification of system, Blue-print – definition how to do really system implementation, Effectible Blue-Print - description how to do real implementation that

is output simulations

Advantage of Rapid Prototyping

In addition to possibility of fast model production, patterns and prototype but mainly production possibility of final lines of modifications and constructed settings of designed product.

Creating of 3D workpiece model makes possible to: Fast creating of complex shape geometry and workpiece dimension

that are expressly described and teamed in screen of monitor Automatic of cut creating and views to machined workpiece, Create and verify other constructional variants of workpieces, Simulated in the space of screen the kinematics it means

movements of particular parts of designed machine tool and to verify possibility of collision becoming,

Realised study of built up the area and assembly kind of workpiece or machine tool

Used generated data for Rapid Prototyping, To set up the programs for machine tool controlling, Simulated the process of workpiece machining in the screen,

include motions optimalization of tool and design of optimal cutting conditions.

Design of the casts up, fixtures and tools for workpiece production.

Rapid Prototyping

Mutual aspect of these Rapid Prototyping methods is that workpiece creating is realised of layer to layer.

Is possible to produce shape difficult workpieces with :hollow inside spaces,Horizontal and diagonal surface,Ribs in the very short time.

Model design for Rapid prototyping

Methods of Rapid Prototyping

I. Stereo lithography (Sl)II. Solid Ground Curing (SGC)III. Selective Laser Sintering (SLS)IV. Fused Deposition Modelling (FDM)V. Laminated Object Manufacturing (LOM)VI. Direct Shell Production Casting (DSPC)VII. Model Market 3D Plotting and Ballistic Particle

Manufacturing (BMP) Multi Jet Modelling

I. Stereo lithography (SL)

It is producing of the workpiece realised layer to layer by hardening of the liquid photopolymer by UV laser (photo polymerization).

On the base of created information about shapes and dimensions are enumerated operated datas that supported the laser beam by XY scanning head.

Stereo lithography (SL)1. Laser

2. Processing head of laser

3. System for moving of support desk

4. Support desk

5. Processing pool

6. CNC operated system

7. Photopolymer

8. Support

9. Machined workpiece

II. Solid Ground Curing (SGC)

Producing proceeding of models based on the photo polymerization where is rim lighted through mask by UV lamp.

This method makes possible to create rangy and shape difficult prototype workpieces.

Solid Ground Curing (SGC)

Advantages: In the SGC process is not needed making stronger, Complication of creating workpieces has not influence to

the time for their production Process of production are not dependenced, Damages layers can be after detecting immediately

milled. Can be produce synchronize more prototype

workpieces.

Solid Ground Curing (SGC)

Used polymers are relatively expensive, Production devices are very large, noisy

and expensive for maintenance, Necessity to remove the wax after

workpiece creating. Little selection of using input materials for

prototype components.

III. Selective Laser Sintering (SLS)

Method based on the principle of the local sintering, eventually melting of powder materials by influence of laser beam.

Used the components of thermoplastic materials, special low melting metal alloys of nickel bronze and of polymers coated powder.

Selective Laser Sintering (SLS)

Advantages: Cheap and no harmed healthy material, Large selection of used materials, Is not needed supported construction, Decreasing of destruction possibility of

inside stresses.

Selective Laser Sintering (SLS)

Disadvantages:

Roughness surface after final modification it means „stairs“ effect,

Porosity of components,

Different intensity in various parts of generated components,

Material transformations are needing cleaning of the production device

Selective Laser Sintering (SLS) – functional scheme

Device for Selective Laser Sintering (SLS)

EOSINT P 360

IV. Fused Deposition Modelling (FDM)

Component is processing by step to step layering of material that is outgoing of heated jet.

Principle of FDM method

V. Laminated Object Manufacturing

Method based on the shape cutting by lasers of special foils and of their gradually layering by sticking.

By this method is possible to produce quantity of components eventually fast because they has scanning only their contours

Principle of Laminated Object Manufacturing

VI. Direct Shell Production Casting

Principle of this method is like the same as in the method of Selective Laser Sintering.

Base material like powder is sticking by liquid binding material.

With this method is possible to generated of ceramic powder various components, forms and casts for processes of straight casting.

VII. Model Market 3D plotting and Ballistic Particle Manufacturing

Material coating is like that drops of material (thermoplast) are darted to process surface and after impact are hardened.

Model Market 3D plotting

Method that work with two pressure jets, the first coating material and second shaped it.

Method Ballistic Particle Manufacturing

Method process only with one pressure head that has five degree of celsius.