Hybrid Layered Manufacturing K'P' Karunakaran

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Hybrid Layered Manufacturing K.P.
Karunakaran S. Suryakumar, Dept. of Mech.
Engg., IIT BombayElitex 2008 India Habitat
Centre, New Delhi, January 17-18, 2008
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Outline

• Definition of Hybrid Layered Manufacturing (HLM)
• Comparison of various HLM Processes
• Arc-based HLM of IIT Bombay
• 3-Axis HLM for Tools
• 5-Axis HLM for Tools with Conformal Cooling Ducts
  and Components
• Conclusions

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Manufacturing Processes
Manufacture
Subtractive
Transformative
Additive
Assembly RP
Machining
Casting Forging Forming
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Additive Manufacturing
Manufacture of objects by building in layers
Video02a-3DP of ZCorp
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Additive Manufacturing
Significant Applications

• Conformal Cooling
• Components with Functionally Gradient Materials
  (FGMs)
• Assemblies without joints
• Shapes impossible or difficult by other processes

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Applications of RP Conformal Cooling
Conventional straight cooling channels.
DLF FhG-IPT, Aachen
METALO Laminated Tooling FhG-ISW, Dresden
3D Printing MIT ProMetal, USA
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Applications of RP Func. Grad. Matrix

• A Functionally Gradient Material (FGM) has
  controlled variation of material composition
  throughout the matrix leading to the desired
  distribution of properties such as color,
  density, hardness, porosity etc. Every natural
  material is FGM!
• Rapid prototypes are inherently anisotropic. RP
  exploits this characteristic for the manufacture
  of FGM by distributing the anisotropy in the
  desired manner. Examples ZCorp color
  prototypes Therics - time release delivery
  drugs Laser Engineered Net Shaping (LENS)
  supports the same for metals.
• Applications medicine, aerospace, gears

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Applications of RP Assemblies
Assemblies without joints! Applications in MEMS
sensors
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Applications of RP Difficult Parts
Parts difficult/ impossible to produce by other
methods
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Comparison of Additive and Subtractive Processes
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Hybrid Layered Manufacturing
Hybrid Layered Manufacturing (HLM) is the
synergic integration of subtractive and additive
manufacturing techniques to retain the benefits
of both while filtering out their limitations. It
will therefore ideally have total automation,
high speed, low cost, high quality of geometry
and material.
HLM typically uses a two level processing i.
Building of near-net 3D shape of the object by
deposition of material in thick layers.
This will be fast but approximate. ii.
Machining the near-net shape fast to the required
finish. If required, it can be preceded by
appropriate heat treatment.
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Types of HLM Processes for Metals
HLM
Powder-bed
Deposition
HLM
Laser
Electron Beam
Arc welding
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Laser-Based HLM
Laser Engineered Net-Shaping (LENS)
A Pair of Moulds Made Using LENS
Video03-LENS

• Too expensive (Rs. 3-4 crores)
• Finish-machining is required
• It is nothing but CNC, i.e.,
• path planning is manual

A near-net turbine blade built using LENS
Repair of a rotor using LENS
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Laser-Based HLM
Laser Augmented Manufacturing (LAM)

• HT preceded finish-machining. These parts were
  functional on Boeing aircraft. So LAM is the best
  example for Rapid Manufacturing of Metallic
  Objects.
• But a commercial failure company was closed
  down in Sep 2005. Reasons
• Poor power efficiency of 2-5 ? 18kW laser
  consumes over 400 kW.
• Poor powder efficiency of 10-15.
• High Argon consumption.
• Safety hazards and bulky and slow

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Laser-Based HLM
Direct Laser Forming (DLS)
Direct Laser Forming (DLS) (Fraunhofer IPT,
Aachen)
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Laser-Based HLM
Precision Object Manufacturing (POM)
Precision Object Manufacturing (POM) (Prof. J.
Mazumder, Michigan State Univ.)
2.4 kW CO2 laser Deposition rate 4 g/min H13
tool steel
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Laser-Based HLM
Direct Metal Laser Sintering (DMLS)
Video02b-EoS-DMLS
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Electron Beam Based HLM
Arcam
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Surface Finish in Various HLM Processes
LENS
LAM
Arcam
DLF
All deposition processes including laser and EB
produce near-net shapes only. Hence
finish-machining is unavoidable in all.
Therefore, why not use the cheaper and safer arc
welding?
MIG-HLM
Laser and EB are overkill for regular engineering
applications for components and tooling!
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Arc-based HLM
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Arc Based HLM
Industrial Case Study Dies of a Massager
Savings 40 in time 30 in cost
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Arc Based HLM
Comparison of Cycle Time MIG-HLM with
Conventional Tool Making
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Arc Based HLM
Comparison of Cost MIG-HLM with Conventional Tool
Making
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3-Axis HLM
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3-Axis HLM
Frequent wire clogging was eliminated by
replacing the 3.5m hose by 1.2m hose. It is now
able to weld over 2 hours non-stop.
We shall start experiments with 0.6mm wire soon.
It will minimize rate of heat input and improve
resolution.
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3-Axis HLM
Face milling position
Welding position
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3-Axis HLM

• The change over from HLM to subtractive CNC is
  simple and quick (just a switch).
• Minimum changes to the machine mechanically and
  electrically.
• The machine is completely protected from
• spatter (using guards)
• heat (using water-cooled table, thin wire)
• spikes (separate earthing, isolation transformer,
  activation of welding through a relay and a limit
  switch, optically isolated DNC connection)

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3-Axis HLM Illustration
Egg template of a refrigerator (Courtesy Godrej)
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3-Axis HLM Illustration
Layer 1
Layer 2a
Layer 2b (Video HLM-IITB)
Layer 3
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3-Axis HLM Illustration
Layer 4
Layer 5
Layer 6
Layer 7
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3-Axis HLM Illustration
Layer 8
Layer 9
Layer 10
Layer 11
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3-Axis HLM Illustration
Layer 12
Layer 13
Layer 14a
Final
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5-Axis HLM
Applications Dies with conformal cooling
ducts Components of Al, Ni and Ti
Video04a-MIG Weld Deposition Video04b-MIG Weld
Deposition
Status Tenders for 5-axis machine will be opened
on Jan 23. Upon placing its order, the robot and
pallet shuttling will be ordered.
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Conclusions

• We are developing a Hybrid Layered Manufacturing
  for making metallic tools and components which
  will combine the benefits of the traditional
  subtractive and recent additive manufacturing
  methods. This research is funded by DIT.
• HLM was proved for tools in Phase I and the
  industrial case study carried out in IGTR shows a
  saving of about 30 in cost and 40 in time.
• 5-axis HLM is being developed in Phase II. It
  will prove this method for dies with conformal
  cooling ducts and intricate components.

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Thank You!