A Conceptual Design and Modeling Framework for Integrated Additive Manufacturing

Abstract

Modeling and simulation for additive manufacturing (AM) is commonly used in industry. Nevertheless, a central issue remaining is the integration of different models focusing on different objectives and targeting different levels of details. The objective of this work is to increase the prediction capability of characteristics and performances of additively manufactured parts and to co-design parts and processes. The paper contributes to this field of research by integrating part's performance model and additive technology process model into a single early integrated model. The paper uses the dimensional analysis conceptual modeling (DACM) framework in an AM perspective to generate causal graphs integrating the AM equipment and the part to be printed. DACM offers the possibility of integrating existing knowledge in the model. The framework supported by a computer tool produces a set of governing equations representing the relationships among the influencing variables of the integrated model. The systematic identification of the weaknesses and contradictions in the system and qualitative simulation of the system are some of the potential uses of the model. Ultimately, it is a way to create better designs of machines and parts, to control and qualify the manufacturing process, and to control three-dimensional (3D) printing processes. The DACM framework is tested on two cases of a 3D printer using the fused filament fabrication (FFF) powder bed fusion. The analysis, applied to the global system formed of the 3D printer and the part, illustrates the existence of contradictions. The analysis supports the early redesign of both parts and AM process (equipment) and later optimization of the control parameters.

Smart additive manufacturing: Current artificial intelligence-enabled methods and future perspectives

“…The framework was the focus, and efficient utilization of big data has not been fully studied. A conceptual design and modelling framework were presented to integrate various simulation and prediction models for the product development process [98]. This framework focused on reflex agents and other types of agents were not considered.…”

A comprehensive review on surface quality improvement methods for additively manufactured parts

“…Metal-based AM has numerous attractive advantages, but some obstacles have prevented further progress. Some of these difficulties are surface quality, dimensional precision, thermal efficiency and fatigue life (Mokhtarian et al , 2018; Moges et al , 2019). In addition, the highly localized processes used in AM can make part manufacture less repeatable and reliable.…”

An Assembly-Oriented Design Framework for Additive Manufacturing

“…The lack of an analysis of what impact AM could have on conceptual design. An issue somehow addressed by the aforementioned conceptual design methods [9][10][11][12]24]. 2.…”

“…Indeed almost none of the current works is led to the consideration of the AM benefits for assembly design in a new product development (NPD) context. Nevertheless, a few contributions [8][9][10][11][12] are targeted at conceptual design for AM. Furthermore, the few assembly-oriented DFAM (A-DFAM) contributions do restrict the scientific issues to part consolidation (PC) [13].…”