A robust process optimization for a powder type rapid prototyper

Yao, Albert W.L.; Tseng, Yen-Chun

doi:10.1108/13552540210431004

Cited by 37 publications

(34 citation statements)

References 4 publications

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“…Each of these variables affects the output part quality and building time in some way. Through initial observations and experience with the 3DP system, it has been found that although most controllable factors have some effect, the output quality is dominated by a few primary control factors (Yao and Tseng, 2002;Stopp et al, 2008), such as layer thickness, location of parts, binder setting saturation value of shell, binder setting saturation value of core, and setting values of shrinkage. In the present investigation, we have examined the effects of these five process parameters on the dimensional and geometric accuracy, and on the quality of the green-parts, either individually or interactively.…”

Section: Determination Of the Major Process Parameters And The Tamentioning

confidence: 98%

“…Combined with the aforementioned two factors of binder consumption and specimen volume, we see the reason why the flexural stress in the shrinkage test is better than in the primary investigation test. We followed the conclusion (the optimal parameter setup value of ZP 100 powder) given by Yao and Tseng (2002) to produce the green-parts in the same manner as Fig. 3 to compare with the optimum results of NCKU-1 powder.…”

Section: Itemmentioning

confidence: 99%

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Manufacturing parts optimization in the three‐dimensional printing process by the Taguchi method

Hsu¹,

Lai

2010

Journal of the Chinese Institute of Engineers

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The functional requirements of three-dimensional printing systems are speed, accuracy and the strength of the green-part. However, these functional indices are significantly affected by the properties of the adopted materials and the manufacturing process parameters of the rapid prototyping machine. The four most important process parameters were systematically investigated in this study. Using the ANOVA analysis techniques of the Taguchi method and adjusting the shrinkage setup values, we determined the optimal parameter setup values for NCKU-1 powder and reduced the dimensional accuracy error to ±0.08 mm, ±0.07 mm and ±0.06 mm in the X-, Yand Z-direction, respectively. The results also show that these optimized parameters can shorten building time by 9.57% and increase flexural stress by 31.27%. Finally, the quality properties were also examined separately for ZP 100 and NCKU-1 powder. It is concluded that building time decreased by 16.5%, binder consumption was reduced by 35.4% and flexural stress increased 172.88% if the powder was changed from ZP 100 to NCKU-1.

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Section: Determination Of the Major Process Parameters And The Tamentioning

confidence: 98%

Section: Itemmentioning

confidence: 99%

Manufacturing parts optimization in the three‐dimensional printing process by the Taguchi method

Hsu¹,

Lai

2010

Journal of the Chinese Institute of Engineers

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“…The 27 rows represent the 27 experiments to be conducted. are the way to determine the significant factors in the optimization process [18]. Fig.…”

Section: ) Selection Of Process Parametersmentioning

confidence: 99%

The Development of Direct Metallic Rapid Tooling System

Luo¹,

Tzou²

2007

IEEE Trans. Automat. Sci. Eng.

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In recent years, rapid tooling (RT) has become increasingly important because of the requirement of rapid manufacturing. RT can be used to produce temporary molds as well as permanent molds in mass production. RT provides more benefits from the design stage to mass production. The objective of this research is to develop the direct metallic RT system and identify process parameters of laser cladding. A 2.5-kW Nd-AG laser system, a metallic powder feeder system, a lateral powder nozzle system, a PC-based motion controller, and a shielding gas-supply system are incorporated for the hardware architecture in the proposed RT system. The critical process parameters influencing the dimensional accuracy were analyzed with Taguchi's experimental design. From the analysis of variance computational results, the factors "Scanning speed" and "Tool path offset" are the influential factors affecting the layer thickness of RT parts. From the experimental results, the dimensional accuracy of the dual nozzle RT system is better than the single-nozzle RT system. Finally, the proposed RT system could fabricate the mold inserts. After finishing the mold inserts and assembling the plenary injection mold, the injection molding machine can generate acrylonitrile butadiene styrene plastic parts with excellent quality.Note to Practitioners-Rapid prototyping (RP) technologies have provided a new way of making models or producing visualization prototype in a fast fashion. However, there is an urgent demand from the industry for much faster ways to make physical prototypes, with the desired material using the appropriate production method. RP technologies have introduced a new generation of RT processes. Producing tooling directly from computer-aided-design (CAD) models is regarded as an important process of reducing the cost and time to market for new products. In this paper, a direct metallic rapid tooling (RT) system is developed to fabricate the metallic parts and molds directly from 3-D CAD models. The experimental investigations are implemented to study the proposed RT system. Using Taguchi's method, the critical performance process parameters have been analyzed. The analysis of variance method is used to decide the important process parameters. The developed RT system can produce the mold inserts directly. After assembling the plenary injection mold, the Acrylonitrile butadiene styrene ABS plastic parts have been generated from this RT mold to demonstrate the success of the process. In the future, it is possible to develop a grading alloy RT system, which can control the ratio of the alloy grading layers. Because the grading alloy rapid mold can use varied metallic powders with varied ratio, the cooling time and the residual stress can be reduced. Furthermore, the RT system can also adopt the coaxial nozzle which can be integrated with the optical system. The advantage of the coaxial nozzle is the independence of the powder supply direction in which the workpiece moves.

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“…Some researchers have focused on optimising operational parameters and strategies. Yao et al [ 11 ] and Tsung-Jung et al [ 8 ] studied different process parameters such us layer thickness, binder saturation and position of parts on the printer table for plaster powder. Suwanprateeb et al [ 12 ] investigated the effect of layer thickness and binder saturation for the same material.…”

Section: Introductionmentioning

confidence: 99%

Towards Functional Parts by Binder Jetting Calcium-Sulphate with Thermal Treatment Post-Processing

et al. 2020

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The objective of our research is to improve the properties of calcium-sulphate hemihydrate parts printed by binder jetting. In this paper, we show the thermal treatment results when using temperature time ramps on binder-jetted ceramic parts without infiltrating. The results show that the mechanical properties of printed parts are improved substantially. Two different thermal cycles were investigated for their effect on the dehydration process of CaSO4·½H2O using infrared analysis. The thermal-treated samples were compared with respect to porosity, surface roughness, compression strength and dimensional and weight variation. The proposed thermal treatment significantly improves the compression strength in a short time, guaranteeing dimensional stability while providing a good surface. This improvement in mechanical properties offers a great chance for using binder-jetted parts as functional components, for example, in the casting field or the medical sector (scaffolds).

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A robust process optimization for a powder type rapid prototyper

Cited by 37 publications

References 4 publications

Manufacturing parts optimization in the three‐dimensional printing process by the Taguchi method

Manufacturing parts optimization in the three‐dimensional printing process by the Taguchi method

The Development of Direct Metallic Rapid Tooling System

Towards Functional Parts by Binder Jetting Calcium-Sulphate with Thermal Treatment Post-Processing

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