Paweł Buń

STRENGTH OF ABS PARTS PRODUCED BY FUSED DEPOSITION MODELLING TECHNOLOGY – A CRITICAL ORIENTATION PROBLEM

Numerous experimental studies, including experiments performed by the authors, have shown that the part orientation during layer deposition has a very strong influence on final strength of a product manufactured by additive Fused Deposition Technology. The paper presents the results of tensile, bending and impact strength tests performed on samples of various orientations, made out of ABS material using FDM technology. The results of these tests allowed discovering a unique phenomenon – with the changing orientation, not only the values of strength indexes change, but macroscopic material behavior under load as well. The transition between a “yield point” and “brittle” material usually happens in a certain range of orientation values, named a critical orientation by the authors. The paper indicates supposed ranges of critical orientation for various types of loads.

Application of additively manufactured polymer composite prototypes in foundry

The paper presents a method, developed by the authors, for manufacturing polymer composites with the matrix manufactured in a layered manner (via 3D printing – Fused Deposition Modeling) out of a thermoplastic material. As an example of practical application of this method, functional prototypes are presented, which were used as elements of foundry tooling – patterns for sand molding. In case of manufacturing prototype castings or short series of products, foundries usually cooperate with modeling studios, which produce patterns by conventional, subtractive manufacturing technologies. If patterns have complex shapes, this results in high manufacturing costs and significantly longer time of tooling preparation. The method proposed by the authors allows manufacturing functional prototypes in a short time thanks to utilizing capabilities of additive manufacturing (3D printing) technology. Thanks to using two types of materials simultaneously (ABS combined with chemically hardened resins), the produced prototypes are capable of carrying increased loads. Moreover, the method developed by the authors is characterized by manufacturing costs lower than in the basic technology of Fused Deposition Modeling. During the presented studies, the pattern was produced as a polymer composite and it was used to prepare a mold and a set of metal castings.

Design and Implementation of a Complex Virtual Reality System for Product Design with Active Participation of End User

The paper presents studies on design and implementation of a complex Virtual Reality system for product design. Main objective of work presented in the paper was to obtain a tool suitable for on-line work with the clients on configuration of visual features of customized city buses. A complex product such as a city bus can have more than 100 visible features (options), which can be changed to obtain infinite configuration possibilities. The paper presents the overview and functions, as well as development process of the created system. Efficiency of the system in the visual configuration process was confirmed by representatives of the company. Capabilities of the system were tested using a sample of users from all the company departments involved in the bus design process. It confirmed high effectiveness of the system in terms of presenting variability of the product features in a clear visual way and improvement of the whole configuration process.

Application of Polystyrene Prototypes Manufactured by FDM Technology for Evaporative Casting Method

e-mail: filip.gorski@put.poznan.pl The paper describes possibilities of using additive manufacturing technologies to manufacture single use casting tooling. The foundries usually cooperate with pattern workshops, which manufacture tooling using conventional processes. In case of patterns of complex shapes, it translates into higher costs and longer time of production. An alternative can be use of additive manufacturing (3D printing), proposed by the authors. The additive manufacturing allows to manufacture complex shapes as quick and cheap as simple shapes, being more fit for the more demanding patterns. The studies performed in this paper were aimed at determination if it is possible to effectively manufacture polystyrene (HIPS) patterns using the low-cost machine working in Fused Deposition Modelling technology and use them directly to manufacture castings out of GJS500-7 cast iron in the investment (burnt pattern) casting process. The paper presents examples of products that can be manufactured this way and also shows problems that appeared during the manufacturing processes.

Virtual Reality System for Learning and Selection of Quality Management Tools

The paper presents an innovative system for teaching of quality tools, facilitating decision-making in scope of solving quality problems in production processes. The solution was created with use of immersive Virtual Reality technology. The system allows two groups of users – production workers and quality staff – to interactively gain knowledge about quality tools or obtain advice on which quality tool should be selected for a given problem. The paper presents the idea behind the system, its functions and basic stages of its creation, as well as course and results of testing of its first prototype. The test results confirm validity of taken assumptions and solutions and allow to perform guidelines for development of the solution.

INFLUENCE OF POST-PROCESSING ON ACCURACY OF FDM PRODUCTS

This paper presents the assessment of the rapid prototyping finishing techniques for printed components. The aim of the study was to compare the element printed with FDM technology before and after the treatment, using 3D scanning techniques. The object was scanned right after manufacturing, then it was subjected to finishing treatment and 3D-scanned again. The assessment of the results was performed using the GOM Inspect software, based on a comparison between scans and nominal model.

Low-Cost 3D Printing in Innovative VR Training and Prototyping Solutions

The paper presents possibility of using a low-cost Fused Deposition Modelling process, realized by MakerBot Replicator 2X machine, in comparison with a professional one – realized by Dimension BST 1200 machine – to build tooling for an innovative training simulation, in accordance with Industry 4.0 guidelines. A physical object was manufactured and then tracked to manipulate in a virtual environment – it was a manual head used during the procedure. The objects were manufactured on two different machines out of ABS material, 3D scanned for accuracy testing and finally possibilities of their use in a VR system were evaluated.

Examination of Effectiveness of a Performed Procedural Task Using Low-Cost Peripheral Devices in VR

The paper presents a Virtual Reality (VR) training system dedicated for interactive course focused on acquisition of competences in the field of manual procedural tasks. It was developed as a response for the growing market demand for low-cost VR systems supporting industrial training. A scenario for the implementation of an elementary manual operation (modified peg-in-hole task) was developed. The aim of the test was to show whether the prepared solution (along with peripheral devices) can be an effective tool for training the activities performed at the production site. The procedural task was performed by specific test groups using various peripheral devices. The paper presents preliminary results of tests regarding evaluation of effectiveness of virtual training, depending on specific peripheral devices used.

Virtual reality training of hard and soft skills in production

The paper1 presents development and test procedure of two Virtual Reality systems for training of skills necessary in a modern production company. The two systems allow teaching hard skills (example: forklift operation) and soft skills (example: quality management tools). Basic ideas, concepts of the virtual courses and their test procedure is presented, along with obtained results.

Virtual Reality Training Application of Medical Procedure

Virtual reality (VR) is a smart technology which may be used as an innovative and effective tool for learning medical and lifesaving procedures. However, in order to fully utilize its potential, it is essential to ensure the effect of immersion – feeling present in a virtual world. It can be achieved by application of advanced interaction devices (such as haptic devices) and immersive Head-Mounted Displays. The paper presents process of creating the VR training application of cricothyrotomy – the surgical, lifesaving procedure of clearing patient airways.