The presented thesis, resulting from a collaboration with Leonardo S.p.A.’s Helicopter Division, focuses on the comparative analysis of two manufacturing technologies: Investment Casting (IC) and Selective Laser Melting (SLM). The research aims to identify guidelines that can support the selection of the best technology to be adopted during the design phase, promoting a ’Design for Technology’ (DfT) approach. The project was developed through an analysis of the state-of-the-art for both technologies and their respective manufacturing processes, which led to the identification of application scenarios in which IC and SLM offer advantages. It became evident that both technologies are suitable for the production of small to medium-sized components with high geometric complexity. However, to gain a comprehensive understanding of the issue, an economic perspective was necessary. For this purpose, a cost model for SLM, already in use within the company, was complemented by a model for IC. The IC model takes preliminary geometric data of the component to be manufactured as input and can adapt to different production volumes. The model’s validation was conducted by comparing it with purchase data for IC parts and the linear dependency between the weight and cost of the component was confirmed. The comparative analysis between IC and SLM has been carried out by applying the two cost models to two case studies: one involving a small component and the other a medium/large component. Therefore, it can be concluded that Investment Casting is the preferred choice for large-scale production scenarios, offering significant economic advantages, especially in the production of large-sized components. On the other hand, SLM finds specific applications, such as the production of extremely complex components or in scenarios of low-volume prototyping. The significance of this research lies in its ability to provide Leonardo Helicopters with a decision making tool of considerable strategic value. This tool enables the company to make informed choices based on economic and technological considerations.
Il lavoro di tesi presentato, frutto di una collaborazione con la Divisione Elicotteri di Leonardo S.p.A., si concentra sull’analisi comparativa di due tecnologie di produzione: l’Investment Casting (IC) e il Selective Laser Melting (SLM). La ricerca è mirata all’individuazione di linee guida che possano supportare la scelta della tecnologia migliore da adottare in fase progettuale, per favorire un approccio "Design for Technology" (DfT). Il progetto è stato elaborato a partire da un’analisi dello stato dell’arte delle due tecnologie e dei rispettivi processi produttivi, che ha condotto ad individuare gli scenari applicativi per cui IC e SLM risultano vantaggiosi. Ne è emerso che le tecnologie sono entrambe adatte alla produzione di componenti di piccole/medie dimensioni, con elevata complessità geometrica. Per ottenere una panoramica completa del problema, tuttavia, è stato necessario affrontare il tema dal punto di vista economico. A tal fine, è stato affiancato ad un modello di costo per SLM, già in uso in azienda, un modello per IC, che prende in input dati geometrici preliminari del componente da realizzare ed è in grado di adattarsi a diversi volumi produttivi. La validazione di questo modello è stata condotta mediante un confronto con dati d’acquisto di parti in IC e si è verificata la dipendenza lineare tra peso e costo del componente. L’analisi comparativa tra IC e SLM si è concretizzata nell’applicazione dei due modelli di costo a due casi studio: un componente di piccole dimensioni e uno di medie/grandi dimensioni. Si è potuto concludere, dunque, che l’Investment Casting si configura come la scelta migliore in scenari di produzione su larga scala, offrendo notevoli vantaggi economici, specialmente per la produzione di componenti di grandi dimensioni. L’SLM, invece, trova applicazione in casi specifici, come nella produzione di componenti estremamente complessi o in scenari di bassa produzione prototipale. L’importanza di questa ricerca risiede nella sua capacità di fornire a Leonardo Elicotteri uno strumento decisionale di rilevante valore strategico, che consente all’azienda di effettuare scelte informate basate su considerazioni economiche e tecnologiche.
Modello di costo della tecnologia di investment casting : confronto con le tecnologie di manifattura additiva
Cinquegrani, Margherita
2022/2023
Abstract
The presented thesis, resulting from a collaboration with Leonardo S.p.A.’s Helicopter Division, focuses on the comparative analysis of two manufacturing technologies: Investment Casting (IC) and Selective Laser Melting (SLM). The research aims to identify guidelines that can support the selection of the best technology to be adopted during the design phase, promoting a ’Design for Technology’ (DfT) approach. The project was developed through an analysis of the state-of-the-art for both technologies and their respective manufacturing processes, which led to the identification of application scenarios in which IC and SLM offer advantages. It became evident that both technologies are suitable for the production of small to medium-sized components with high geometric complexity. However, to gain a comprehensive understanding of the issue, an economic perspective was necessary. For this purpose, a cost model for SLM, already in use within the company, was complemented by a model for IC. The IC model takes preliminary geometric data of the component to be manufactured as input and can adapt to different production volumes. The model’s validation was conducted by comparing it with purchase data for IC parts and the linear dependency between the weight and cost of the component was confirmed. The comparative analysis between IC and SLM has been carried out by applying the two cost models to two case studies: one involving a small component and the other a medium/large component. Therefore, it can be concluded that Investment Casting is the preferred choice for large-scale production scenarios, offering significant economic advantages, especially in the production of large-sized components. On the other hand, SLM finds specific applications, such as the production of extremely complex components or in scenarios of low-volume prototyping. The significance of this research lies in its ability to provide Leonardo Helicopters with a decision making tool of considerable strategic value. This tool enables the company to make informed choices based on economic and technological considerations.File | Dimensione | Formato | |
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2023_12_Cinquegrani_Tesi_01.pdf
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Descrizione: Elaborato di Tesi
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2023_12_Cinquegrani_Executive Summary_02.pdf
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Descrizione: Executive Summary
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https://hdl.handle.net/10589/214211