Modern Machine Shop

FEB 2018

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ADDITIVE INSIGHTS MMS FEBRUARY 2018 40 Understanding Industrial 3D Printing AUTHOR | Timothy Simpson Professor of Engineering Design & Manufacturing Pennsylvania State Univeristy to be made with a conventional manufacturing process and not with AM, the restrictive nature of DFAM applies most in this use case (see graphic). Adapt for AM In this use case, the geometry is given, but it can be modified to minimize or avoid the restrictive aspects of AM (overhangs, support structures, thin walls, thick sections and so on). In the piston crown example described in December ( tional ), we adapted the original design and were able to reduce the support structures (restrictive DFAM) while enhancing the internal geometry with conformal cooling channels (opportunistic DFAM). The adapted design printed faster, required almost no postprocessing and offered improved heat transfer for better performance. Adapting designs for AM reduces the restrictive aspects of the process that can drive up cost and takes advantage of oppor- tunities to enhance performance. So if replicating with AM compares apples to apples, then adapting for AM is like comparing apples to oranges. Optimize for AM In this use case, the geometry is designed specifi- cally for AM. This is where generative design tools such as topology optimization, lattice structures, biomimicry and so on come into play and leverage the opportunistic aspects of AM. The lightweight oil and gas part highlighted in January ( gbm. media/lattices ) is an example of this. By using lattice structures and thinking about part orienta- tion and overhangs during the design process, we were able to additively manufacture a part that was lighter weight, required no support structures and permitted material substitution that led to enhanced part life. If the first two use cases are akin to comparing fruit to fruit, then this third use case is like comparing fruits to vegetables—you can get the same nutrients out of each, but what you might eat is an entirely different type of food, one that you may not have considered before. Similarly, with AM, we can rethink what we are trying to achieve and not be as constrained by the process that will be used to make it. This is where AM can take us. IBAG Micro Line Means More! n More compact models to fit more machines n More tool accuracy-less than 1 micron TIR n More applications-turrett mounted spindles n More user-friendly-easier to install n More cycle time savings for faster ROI IBAG Micro Line high speed spindles for Swiss machining. We have the size you need-16, 19, 20, 22, 25 and 33 mm diameter spindles. Spindle speeds to 120,000 RPM. Power to 390 watts. ROI from the start. Tel 203-407-0397 Fax. 203-407-0516 e-mail: See Us at MD&M West Booth 250

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