ADDITIVE MANUFACTURING (18ME741)

ADDITIVE MANUFACTURING

Course Code 18ME741
CIE Marks 40
Teaching Hours /Week (L:T:P) 3:0:0
SEE Marks 60
Credits 03
Exam Hours 03

Course Learning Objectives:

 To know the principle methods, areas of usage, possibilities and limitations of the Additive Manufacturing technologies.
 To be familiar with the characteristics of the different materials those are used in Additive Manufacturing.
 To know the principles of polymerization and powder metallurgy process, extrusion-based system printing processes, sheet lamination processes, beam deposition processes, direct write technologies and Direct Digital Manufacturing.
 To get exposed to process selection, software issues and post-processing.

Module-1

Introduction and basic principles: Need for Additive Manufacturing, Generic AM process, stereoli thography or 3dprinting, rapid proto typing ,the benefits of AM, distinction between AM and CNC machining, other related technologies- reverse engineering technology. Development of Additive Manufacturing Technology: Introduction, computers, computer-aided sign technology,other associated technologies, the use of layers, classification of AM processes, metals ystems, hybrid systems, milestones in AM development. Additive Manufacturing Process chain: Introduction, the eight steps in additive manufacture, variations from one AM machine to another, metal systems, maintenance of equipment, materials handling issues, design for AM, and application areas.

Module-2

Photo polymerization processes: Stereolitho graphy (SL), Materials, SL resin curing process, Micro-stereoli thography, Process Benefits and Drawbacks, Applications of Photo polymerization Processes. Powder bedfusion processes: Introduction, Selective laser Sintering (SLS), Materials, Powder fusion mechanism, SLS Metal and ceramic part creation, Electron Beam melting (EBM), Process Benefits and Drawbacks, Applications of Powder Bed Fusion Processes. Extrusion-based systems: Fused Deposition Modelling (FDM), Principles, Materials, Plotting and path control, Bio-Extrusion, Process Benefits and Drawbacks, Applications of Extrusion-Based Processes.

Module-3

Printing Processes: evolution of printing as an additive manufacturing process, research achievements in printing deposition, technical challenges of printing, printing process modeling, material modification methods, three-dimensional printing, advantages of binder printing Sheet Lamination Processes: Materials, Laminated Object Manufacturing (LOM), Ultrasonic Consolidation (UC), Gluing, Thermal bonding, LOM and UC applications. Beam Deposition Processes: introduction, general beam deposition process, description material delivery, BD systems , process parameters, typical materials and microstructure, processing–structure–properties relationships, BD benefits and drawbacks. Direct Write Technologies: Background ,ink -basedDW,laser transfer, DW thermals pray,DW beam deposition,DW liquid-phase directde position.

Module-4

Guidelines for Process Selection: Introduction, selection methods for apart, challenges of selection, example system for preliminary selection, production planning and control. Software issues for Additive Manufacturing: Introduction, preparation of cad models – the STL file, problems with STL files, STL file manipulation. Post- Processing: Support material removal, surface texture improvements, preparation for use as a pattern, property enhancements using non-thermal techniques and thermal techniques.

Module-5

The use of multiple materials in additive manufacturing: Introduction, multiple material approaches, discrete multiple material processes, porous multiple material processes, blended multiple material processes, commercial applications using multiple materials, future directions. AM Applications: Functional models, Pattern for investment and vacuum casting, Medical models, art models, Engineering analysis models, Rapid tooling, new materials development, Bi-metallic parts, Remanufacturing. Application: Examples for Aerospace, defense, automobile, Bio-medical and general engineering industries. Direct digital manufacturing: Align Technology, siemens and phonak, DDM drivers, manufacturing vs. prototyping, life- cycle costing, future of direct digital manufacturing.

Course Outcomes: At the end of the course the student will be able to:

CO1: Demonstrate the knowledge of the broad range of AM processes, devices, capabilities and materials that are available.
CO2: Demonstrate the knowledge of the broad range of AM processes, devices, capabilities and materials that are available.
CO3: Understand the various software tools, processes and techniques that enable advanced/additive manufacturing.
CO4: Apply the concepts of additive manufacturing to design and create components that satisfy product development/prototyping requirements, using advanced/additive manufacturing devices and processes.
CO6: Understand characterization techniques in additive manufacturing.
CO7: Understand the latest trends and business opportunities in additive manufacturing.

Question paper pattern:

 The question paper will have ten full questions carrying equal marks.
 Each full question will be for 20 marks.
 There will be two full questions (with a maximum of four sub- questions) from each module.
 Each full question will have sub- question covering all the topics under a module.
 The students will have to answer five full questions, selecting one full question from each module.

Textbooks

1 Additive Manufacturing Technologies Rapid Prototyping to Direct Digital Manufacturing I. Gibson l D. W. Rosen l B. Stucker Springer New York Heidelberg Dordrecht, London ISBN: 978-1-4419-1119-3e-ISBN: 978-1-4419-1120-9 DOI10.1007/978-1-4419-1120-9

Reference Books

1Rapid Prototyping: Principles & Applications Chua Chee Kai, Leong Kah Fai World Scientific 2003
2 Rapid Prototyping: Theory & Practice Ali K. Kamrani, Springer 2006 EmandAbouel Nasr,
3 Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and Rapid Tooling” D.T. Pham, S.S. Dimov Springer 2001
4 Rapid Prototyping: Principles and Applications in Manufacturing RafiqNooran John Wiley & Sons 2006
5 Additive Manufacturing Technology Hari Prasad, A.V.Suresh Cengage 2019
6 Understanding additive manufacturing: rapid prototyping, rapid tooling, rapid manufacturing Andreas Gebhardt Hanser Publishers 2011