Additive manufacturing methods were started to be developed in the late 70s and have been using in many different fields with various types until today. Including the develop models are using plastic, ceramic composite raw materials as well as metal materials. It is possible to see a very wide perspective in terms of usage areas. One of the types of Extrusion Based Additive Manufacturing has been using in just a few years back to produce high-quality final state parts. In numerous fields utilization of AM is slightly increasing such as automotive, dental and tool design applications. AM procure complex geometry requirements of end parts expeditiously compared to traditional manufacturing methods and the importance of design becomes more important so, AM pledge to expanse using fields for future applications. The aim of this paper is to analyze the effect of printing parameters (printing velocity, extruder temperature, bed temperature, nozzle diameter), to evaluate shape complexity, to understand the thermal distribution and tool applications of T15 tool steel. The study was carried out by Creality Ender-3 3D machine with under the customization of Pellet V3 Extruder. A combination of CAD model and slicing software and technology is used to develop and optimize the resulting G-Code. Using different levels and a combination of levels of design parameters, various parts were printed. The obtained parts were exposed to a two-step debinding process and a one-step sintering process to attain the final shape. For optimization process parameters, were calculated the deviation of green state parts relevant to CAD files and brown state parts relevant to their green state forms. Measuring devices were used to evaluate properties of parts. Several samples and repeated measurements support the validation of the experimental results. A new screw drive using machine were built which uses metal as a raw material. Its working processes were investigated. The specimens were measured in consideration of part properties such as weight change, density, microhardness, surface roughness, printing error (vol%) and visual quality index (%). The various correlations between the properties and their parameters were also evaluated.
Verso la fine degli anni settanta furono sviluppati i metodi di produzione additiva (denominati in seguito “AM“), i quali vengono tuttora usati in molti campi eterogenei tra loro, tra cui in modelli di sviluppo che impiegano materie plastiche, materiali compositi ceramici nonché materiali metallici sicché, attualmente, è possibile riscontrarne un ampio utilizzo. Fin da qualche anno una tipologia di produzione additiva basata sull’estrusione viene utilizzata per produrre parti di stato finale di alta qualità. In numerosi settori, l'utilizzo dei AM è in lieve aumento, come ad esempio nelle applicazioni automobilistiche, dentistiche e di progettazione di utensili. I cosiddetti AM rispettano con facilità i complessi requisiti di geometria delle parti terminali (rispetto ai metodi di produzione tradizionali), sicché l'importanza della loro progettazione diventa sempre più importante e, pertanto, essi rappresentano un metodo idoneo per i futuri campi di applicazioni. Lo scopo del presente scritto è analizzare l'effetto dei parametri di stampa (i.e. velocità di stampa, temperatura dell'estrusore, temperatura del letto, diametro dell'ugello), valutare la complessità della forma nonché comprendere la distribuzione termica e le applicazioni degli T15 acciaio per utensili. Il presente studio è stato condotto utilizzando la stampante 3D Creality Ender-3, personalizzando l’estrusore Pellet V3. Sono stati, inoltre, combinati il modello CAD, il software e la tecnologia di slicing al fine di sviluppare e ottimizzare il codice G risultante. Utilizzando i differenti livelli di parametri progettuali nonché la loro combinazione, sono state stampate numerose parti. Quest’ultime sono state esposte ad un processo di sbavatura di due fasi nonché ad un processo monofase di sinterizzazione con lo scopo di ottenere la forma finale. Per i parametri del processo di ottimizzazione, sono state calcolate la deviazione delle parti di stato verde, relative ai file CAD, e le parti di stato marrone, relative alle loro forme di stato verde. Sono stati utilizzati, inoltre, dispositivi di misurazione per valutare le proprietà delle parti. I numerosi campioni e le ripetute misurazioni convalidano i risultati sperimentali. È stato costruito un avvitatore che utilizza il metallo come materia prima e i cui processi lavorativi sono stati oggetto del presente studio. I campioni sono stati, infine, misurati in considerazione delle proprietà del pezzo, quali la variazione di peso, la densità, la microdurezza, la rugosità superficiale, l’errore di stampa (vol%) e l’indice di qualità visiva (%). Sono state, inoltre, valutate le varie correlazioni tra le proprietà e i loro parametri.
Design and development of rapid metal tools using extrusion based additive manufacturing
DURMAZ, ILHAN
2018/2019
Abstract
Additive manufacturing methods were started to be developed in the late 70s and have been using in many different fields with various types until today. Including the develop models are using plastic, ceramic composite raw materials as well as metal materials. It is possible to see a very wide perspective in terms of usage areas. One of the types of Extrusion Based Additive Manufacturing has been using in just a few years back to produce high-quality final state parts. In numerous fields utilization of AM is slightly increasing such as automotive, dental and tool design applications. AM procure complex geometry requirements of end parts expeditiously compared to traditional manufacturing methods and the importance of design becomes more important so, AM pledge to expanse using fields for future applications. The aim of this paper is to analyze the effect of printing parameters (printing velocity, extruder temperature, bed temperature, nozzle diameter), to evaluate shape complexity, to understand the thermal distribution and tool applications of T15 tool steel. The study was carried out by Creality Ender-3 3D machine with under the customization of Pellet V3 Extruder. A combination of CAD model and slicing software and technology is used to develop and optimize the resulting G-Code. Using different levels and a combination of levels of design parameters, various parts were printed. The obtained parts were exposed to a two-step debinding process and a one-step sintering process to attain the final shape. For optimization process parameters, were calculated the deviation of green state parts relevant to CAD files and brown state parts relevant to their green state forms. Measuring devices were used to evaluate properties of parts. Several samples and repeated measurements support the validation of the experimental results. A new screw drive using machine were built which uses metal as a raw material. Its working processes were investigated. The specimens were measured in consideration of part properties such as weight change, density, microhardness, surface roughness, printing error (vol%) and visual quality index (%). The various correlations between the properties and their parameters were also evaluated.| File | Dimensione | Formato | |
|---|---|---|---|
|
2019_12_durmaz.pdf
non accessibile
Descrizione: Thesis Report
Dimensione
4.66 MB
Formato
Adobe PDF
|
4.66 MB | Adobe PDF | Visualizza/Apri |
I documenti in POLITesi sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
https://hdl.handle.net/10589/151522