Response surface‐based simulation modeling for selective laser sintering process

Singh, Amit Kumar; Prakash, R.

doi:10.1108/13552541011083362

Cited by 14 publications

(10 citation statements)

References 40 publications

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“…To identify the optimal curing speed of the small tool under different parameters settings such as curing gap, UV power, base material, and curing strategy, a statistical methodology based on the design of experiments (DOE) is performed. As shown in similar studies for the machining and AM processes [25][26][27][28], the statistical study based on DOE has a good capability in identifying appropriate manufacturing process settings.…”

Section: Process Settings Of Multitool Cnc Accumulation Systemmentioning

confidence: 96%

Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

Pan

Zhou²,

Chen

et al. 2014

Journal of Manufacturing Science and Engineering

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In engineering systems, features such as textures or patterns on curved surfaces are common. In addition, such features, in many cases, are required to have shapes that are conformal to the underlying surfaces. To address the fabrication challenge in building such conformal features on curved surfaces, a newly developed additive manufacturing (AM) process named computer numerically controlled (CNC) accumulation is investigated by integrating multiple tools and multiple axis motions. Based on a fiber optical cable and a light source, a CNC accumulation tool can have multi-axis motion, which is beneficial in building conformal features on curved surfaces. To address high resolution requirement, the use of multiple accumulation tools with different curing sizes, powers, and shapes is explored. The tool path planning methods for given cylindrical and spherical surfaces are discussed. Multiple test cases have been performed based on a developed prototype system. The experimental results illustrate the capability of the newly developed AM process and its potential use in fabricating conformal features on given curved surfaces.

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Section: Process Settings Of Multitool Cnc Accumulation Systemmentioning

confidence: 96%

Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

Pan

Zhou²,

Chen

et al. 2014

Journal of Manufacturing Science and Engineering

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“…The analytical model of a moving laser beam is normally considered as a point source of heat, which has an energy of g W. 36 The energy will be released continuously over time moving along the positive x -axis with a constant velocity u , in a fixed layer of material maintained at a fixed material temperature. The incident laser beam in analytical modeling is assumed to be point source.…”

Section: Fea Simulation Modelmentioning

confidence: 99%

Density characteristics of laser-sintered three-dimensional printing parts investigated by using an integrated finite element analysis–based evolutionary algorithm approach

Vijayaraghavan

Garg

Wong

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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An integrated finite element analysis–evolutionary algorithm simulation approach is proposed in this work to model the density characteristics of the three-dimensional printing, specifically for selective laser sintering process. The approach consists of modeling sintering phenomenon by finite element analysis simulation, which is further fed into an evolutionary algorithm cluster comprising genetic programming. The integrated approach is useful to model the functional relationship of density characteristic of selective laser sintering–fabricated components with respect to laser power, scan velocity and scan spacing. Performance of the proposed model is evaluated against the actual results obtained from the literature. We find that our proposed finite element analysis–evolutionary algorithm model is able to model the selective laser sintering process very well, which can be used to complement the analytically and experimentally obtained results. For the validation of the robustness of the model, we also conducted sensitivity and parametric analyses and investigated the specific influence, and variation, of each of the input process parameters on the density of the selective laser sintering–fabricated component. It was found that scan spacing has the least influence, whereas scan velocity has the highest influence on the density of the selective laser sintering–fabricated component. Non-linear relationships unveiled between the process parameters highlight the capability of the model in simulating the density characteristic of the complex selective laser sintering process in uncertain input conditions.

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“…Several studies analyze the maximum melt temperatures in LS by simulation models [3,[8][9][10][11] or by measuring temperatures [8,[12][13][14]. However, temperature ranges found show big differences between the studies.…”

Section: State Of the Artmentioning

confidence: 99%

Understanding the decisive thermal processes in laser sintering of polyamide 12

Witt

2015

AIP Conference Proceedings

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Abstract. Due to the advancements during the last decade, the laser sintering process has achieved a high technical level, which allows parts being used for Rapid Manufacturing applications. However, the processes still show a poor reproducibility of part quality. Furthermore, process interruptions or defective parts still occur regularly. The knowhow and expertise needed to avoid these kind of problems is still insufficient. The temperature increase in the powder bed during laser exposure is the driving force in laser sintering of plastics. The resulting part properties strongly depend on the interaction of melt temperature and melt viscosity caused by the laser power input in the powder bed. Additionally, cooling conditions and temperature gradients in the powder bed significantly influence the accuracy and especially the warpage of parts. However, literature provides only little information on these decisive thermal processes. Therefore, additional information is necessary to improve process understanding as well as part properties in laser sintering. In a first approach, a high-speed thermal imaging system is implemented into a LS-machine in order to measure the melt temperatures during and after laser exposure as a function of different process parameters. The measured data show significant correlations between temperatures and part properties. It turns out that especially the melt temperature after laser exposure has a strong influence on the resulting part properties. In a second approach, detailed measurements of temperature distributions within the powder bed are performed while using wireless temperature sensors. In addition, the influence of different heater parameter settings on the cooling conditions is investigated by using a new Advanced Temperature Guiding system with 15 single heater cycles. The results of the study lead to an enhanced understanding of the thermal processes in laser sintering and enable a significant improvement of processing conditions.

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Response surface‐based simulation modeling for selective laser sintering process

Cited by 14 publications

References 40 publications

Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

Density characteristics of laser-sintered three-dimensional printing parts investigated by using an integrated finite element analysis–based evolutionary algorithm approach

Understanding the decisive thermal processes in laser sintering of polyamide 12

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