Radosław Wichniarek

INFLUENCE OF PROCESS PARAMETERS ON DIMENSIONAL ACCURACY OF PARTS MANUFACTURED USING FUSED DEPOSITION MODELLING TECHNOLOGY

The paper presents the results of experimental study – part of research of additive technology using thermoplastics as a build material, namely Fused Deposition Modelling (FDM). Aim of the study was to identify the relation between basic parameter of the FDM process – model orientation during manufacturing – and a dimensional accuracy and repeatability of obtained products. A set of samples was prepared – they were manufactured with variable process parameters and they were measured using 3D scanner. Significant differences in accuracy of products of the same geometry, but manufactured with different set of process parameters were observed.

Computation of Mechanical Properties of Parts Manufactured by Fused Deposition Modeling Using Finite Element Method

The paper focuses on a problem of evaluation of strength of products manufactured using Fused Deposition Modelling technology. The presented research was aimed at developing a method for computation of deformation and stresses in any product manufactured using FDM technology, with consideration of important, strength-affecting process parameters. Finite Element Method calculations were realized using digital CAD models of the products, obtained by simulation of FDM process in a virtual environment. These models represent the macrostructure of additively manufactured elements. Results of calculations for sample geometries were verified by experimental studies. The obtained results are mostly correct, changes in approach are needed to make the computations possible to be performed in shorter time and with better results.

Multi-agent System to Support Decision-Making Process in Ecodesign

In the paper the application of multi-agent system to support decision-making process in ecodesign is presented. The ecodesign term is highlited either as the design problem or from the point of view of regulations. The structure of agent-system supporting the designer during the design process is showed. The basis of special kind of product model, that is the extension of standard 3D product model, called recycling-oriented product model (RmW), are described. The example results of analysis, based on real household appliance model, are presented.

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.

Multi-agent system to support decision-making process in design for recycling

In this paper, the application of multi-agent system to support decision-making process in design for recycling is presented. The design for recycling term is highlighted either as the design problem or from the point of view of regulations. The structure of agent system supporting the designer during the design process is showed. The basis of special kind of product model, that is the extension of standard 3D product model, called recycling-oriented product model, is described. The example results of analysis, based on real household appliance model, are presented.

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.

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.