JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Pre-requisites

Manufacturing Processes, Engineering Materials

Course Objectives:

• To understand the fundamental concepts of Additive Manufacturing (i.e. Rapid Prototyping) and 3-D printing, its advantages and limitations.
• To classify various types of Additive Manufacturing Processes and know their working principle, advantages, limitations etc.
• To have a holistic view of various applications of these technologies in relevant fields such as mechanical, Bio-medical, Aerospace, electronics etc.

Course Outcomes:

• Describe various CAD issues for 3D printing and rapid prototyping and related operations for STL model manipulation.
• Formulate and solve typical problems on reverse engineering for surface reconstruction from physical prototype models through digitizing and spline-based surface fitting.
• Formulate and solve typical problems on reverse engineering for surface reconstruction from digitized mesh models through topological modelling and subdivision surface fitting.
• Explain and summarize the principles and key characteristics of additive manufacturing technologies and commonly used 3D printing and additive manufacturing systems.
• Explain and summarize typical rapid tooling processes for quick batch production of plastic and metal parts.

UNIT - I

Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping, Advantages and Limitations of Rapid Prototyping, Commonly used Terms, Classification of RP process, Rapid Prototyping Process Chain: Fundamental Automated Processes.

UNIT - II

Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused Deposition Modeling (FDM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies.

UNIT - III

Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT), Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification; Indirect Rapid Tooling Methods: Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Die casting, Sand Casting, 3D Keltool process. Direct Rapid Tooling : Direct AIM, LOM Tools, DTM Rapid Tool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP

UNIT - IV

Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.

UNIT - V

RP Applications: Application - Material Relationship, Application in Design, Application in Engineering, Analysis and Planning, Aerospace Industry, Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning and simulation of complex surgery, Customized Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and Anthropology, Visualization of Biomolecules.

TEXT BOOKS:

• 1. Rapid prototyping; Principles and Applications /Chua C.K., Leong K.F. and LIM C.S/World Scientific Publications
• 2. Rapid Manufacturing /D.T. Pham and S.S. Dimov/Springer

REFERENCE BOOKS:

• 1. Terry Wohlers, Wholers Report 2000, Wohlers Associates
• 2. Rapid Prototyping and Manufacturing /PaulF.Jacobs/ASME