MECHANICAL ENGINEERING, I M.TECH.

II SEM (AMS)
ASSIGNMENT - 1
Roll No. : 24071D3307 PATLOLA CHANDRA SEKHAR

UNIT - 1
1. Describe Additive manufacturing process chain

ADDITIVE MANUFACTURING: The process of creating a tangible model from a digital

CAD 3D model using a 3D printer by layering material is known as additive manufacturing
(AM). While “3D printing” is more general, AM is usually linked to industrial and
manufacturing uses.

AM Process Chain:

Additive Manufacturing encompasses multiple stages, ranging from the CAD description to
the physical outcome. The procedure will differ according to the product. Smaller and
simpler products probably utilize AM solely for visualization, while larger and more complex
products may integrate AM at various stages and iterations during their development.
Additionally, during the initial phases of product development, rough components may be
required, and AM is typically employed because of its quick manufacturing ability. As
components move forward in the process, they may require cleaning and post-processing
(like coating and sanding) before use; because of the intricate designs that can be produced
without tooling, rapid prototyping proves beneficial in this context.

Fig. Additive Manufacturing Process chain

Step – 1 CAD Model: CAD models that fully describe the external geometry are required for
all AM parts. Any professional CAD solid modelling software can be used to create this, but
the final product must be a 3D solid or surface model. To create such an image, reverse
engineering equipment (for example, laser and optical scanning) can also be used.

Step – 2 Conversion to STL: Once the digital model is completed, stereolithography must
be created using the STL (Standard Tessellation Language) file format. This format is
supported by almost all CAD Systems and it serves as the means of communication for AM
machines. Calculating the model's slices is based on the STL file.

Step – 3 Transfer to Machine: In the third step, the STL file is sent to the AM machine.
This step allows for adjustments to the build’s position and size so that it is correct. The AM
machine is controlled by a computer. The AM machine is operated by the computer, which
produces the necessary instructions as G-codes and M-codes based on the specified process
parameters. It produces instructions automatically, and any necessary corrections for
improving the part to be built can be made.

Step – 4 Setup: The equipment must be set up before construction begins. The settings may
include power, speed, layer thickness, and several other parameters related to material and
process constraints, among others.

Step – 5 Build: The fifth step involves constructing the CAD model by melting it layer by
layer. This process can be either partially or fully automated; however, online monitoring is
often performed to ensure that the machine does not run out of material or encounter a
software error.

Step – 6 Part Removal: After the part is manufactured, it must be removed from the process,
which is usually done by hand. This might necessitate engagement with the machine, which
could be equipped with safety interlocks to guarantee, for instance, that the operating
temperatures are adequately low or that no parts are in motion.

Step – 7 Post-processing: After the build, the part may require some post-processing before
it is fully completed. Depending on the material and additive manufacturing process used,
some components may require machining, cleaning, polishing, removal of support structures,
hot isostatic pressing (HIP), and heat treatments.
Step – 8 Application: At this point, the part may be ready to use. It may still require some
further treatment, such as painting or assembly with other parts, before it can be fully used.
As an example, they might need to be primed and painted in order to achieve an acceptable
surface texture and finish. If the finishing requirements are highly demanding, treatments can
be time-consuming and arduous. It may also be necessary to assemble them with other
electronic or mechanical components in order to create a final product or model.

2. Explain the classification of Additive Manufacturing Process.

Additive Manufacturing refers to various manufacturing methods that construct components

one layer at a time. They differ in how they create plastic and metal components, as well as in
aspects such as material choice, surface finish, durability, and the speed and cost of
production. Various forms of 3D printing exist, including:
i. Stereolithography (SLA)
ii. Selective Laser Sintering (SLS)
iii. Fused Deposition Modeling (FDM)
iv. Digital Light Process (DLP)
v. Multi Jet Fusion (MJF)
vi. PolyJet
vii. Electron Beam Melting (EBM)
viii. Direct Metal Laser Sintering (DMLS)

Based on different forms of input materials, 3D printing technology can be divided into solid,
liquid, and powder.

1. Solid based
i. Laminated Object Manufacturing (LOM)
ii. Fused Deposition Modelling (FDM)
iii. Wire and Arc Additive Manufacturing (WAAM)
iv. Electron Beam Free Form Fabrication (EBF3)
2. Liquid Based
i. Stereolithography (SLA)
ii. Digital Light Processing (DLP)
 iii. Material Jetting (MJ)
3. Powder Based
i. Selective Laser Sintering (SLS)
ii. Electron Beam Melting (EBM)
iii. Selective Lase Melting (SLM)
iv. Binder Jetting (BJ)
v. High Speed Sintering (HSS)

Fig. Classification of AM Process

3. What are the differences between Additive Manufacturing and CNC

process?

The main differences between Additive and CNC Manufacturing processes are as follows:

S.No. Additive Manufacturing CNC Process

It is additive process where material is It is a subtractive process where material is
1.
added layer by layer. removed from solid block.
2. Creates prototypes models first by usingIt turns, drilling, and other machining processes
computers and 3D printing equipment using computers and robotics.
 You must do post-printing to surface Surface finishing can be done by machining like
3. finish by sanding or blowing because smoothing, stepping, etc.
layering makes a rough surface.
4. It is a slow process. It is a fast process.

It can be used with limited materials like Suitable for all types of materials like metal,
5.
plastics and metals. plastic, wood, composites, and glasses
6. It is best suited for small items. It is best suited for large items.

A machine operator is not needed in this Here, the machine operator required to monitor
7. process because the software will take the CNC machine
care of the 3D printer.
8. Less expensive More expensive

9. Suitable for small batch production Suitable for large-scale production

The finished product will have a weak The finished product will have a strong structure.
10.
structure

UNIT - 2
1. Explain the principle, working process, advantages, disadvantages, and
applications of Stereo Lithography Apparatus(SLA) & Solid Ground
Curing(SGC)
Stereo Lithography Apparatus (SLA):
A Stereolithography Apparatus (SLA), which can also be referred to as a stereolithography
machine or SLA 3D printer, is a category of 3D printer that utilizes photopolymerization to
generate solid 3D objects from liquid photopolymer resin. A UV laser or light source is used
in the process to selectively cure the resin layer by layer, thereby constructing the object.
Principle:
 The UV laser activates the carbon chains of the monomer in the liquid resin during photo
polymerization, initiating a chemical reaction that creates solid cross linked bonds.
 This leads to robust, long-lasting components featuring intricate details and sleek
surfaces.
 To ensure precise laser direction, a system of mirrors known as galvos directs the beam
along a predetermined path, guaranteeing that the entire cross-sectional area of the model
is cured into a completely solid structure.

Fig. Stereo Lithography Apparatus(SLA)

Working:
 In the Stereolithography process, a layer of liquid resin on the build platform is solidified
by the action of a precision-controlled laser beam. For building the intended component
in layers, this controlled solidification is essential.
 This 3D printing method can produce prototypes of high detail, complex shapes, and
smooth surfaces. As a result, it is crucial to fields including engineering, product design,
and healthcare.
 The start of the SLA process involves dividing a 3D computer model into many cross-
sectional layers that direct the laser's movement. With each layer, the laser moves back
and forth, hardening the liquid resin and bonding it to the underlying layer.
 With this precise layering method, the digital model can be reproduced accurately,
yielding functional prototypes for design validation and testing.
 With SLA technology, the pace of product development has increased significantly,
giving engineers and designers the ability to realize their creative ideas with extraordinary
speed and precision.
Advantages of SLA:
 High precision and fine detail in the final product.
 Smooth surface finish, reducing the need for post-processing.
 Versatility in creating intricate and complex geometries.
 Supports a wide range of materials for different applications.
 Rapid prototyping enables quick design iteration.
Disadvantages of SLA:
 Limited in building large-sized objects.
 Post-processing may be required to remove excess resin and achieve desired aesthetics.
 Material choices are often limited compared to other 3D printing methods.
 Handling liquid resins can be messy and require safety precautions.
 Stereo lithography machines tend to be relatively expensive.
Applications of SLA:
 Prototyping and product development
 Medical and dental models
 Custom jewelry and fashion accessories
 Rapid tooling and manufacturing aids
 Educational models
 Engineering and aerospace components
 Consumer electronics components

Solid Ground Curing (SGC):

A Solid Ground Curing (SGC) is an additive manufacturing method that uses photopolymers
to build 3D models by applying a thin layer of photosensitive resin and curing it with UV
light via a mask. SGC enhances the speed of the process by exposing the entire layer
simultaneously, as opposed to stereolithography, which relies on a laser. Then, each layer is
milled to produce a solid model.

Principle:
 The solid ground curing method employs a general process for hardening photopolymers
by fully lighting and curing the entire surface, with the aid of specially prepared masks.
 The SGC process cures each layer of the prototype by exposing it to an ultraviolet (UV)
lamp, rather than using laser scanning.
 This ensures that all parts of a layer are cured at the same time and do not need any post-
curing procedures.

Fig. Solid Ground Curing(SGC)

Working:
 The geometric model of the part and the intended layer thickness are used to calculate the
cross section of each slice layer.
 The optical mask is produced in accordance with each cross section.
 Once leveled, a thin layer of liquid photopolymer is applied to the platform's surface.
 The mask for the current layer is placed over the liquid resin's surface, while a high-
power UV lamp exposes the resin.
 An aerodynamic wiper eliminates the residual liquid from the work piece.
 A layer of molten wax is applied to the workpiece to fill gaps. A cold plate is applied to
the wax in order to solidify it.
 A milling disk is used to trim the layer surface to the desired thickness.
 A liquid polymer coats the current workpiece, and steps 4 to 7 are repeated for each upper
layer until the topmost layer is processed.
 Upon completion of the part, the wax is melted away.
Advantages of SGC:
 No support structure is required, as the wax provides support for the model in every
direction.
 The volume of the production environment is equivalent to what we obtain from
Stereolithography. It is possible to produce large components in a short time. The
dimensional accuracy is satisfactory.
 It can construct layers of 0.1 mm thickness, one on top of the other.
 It is very quick and has a decent level of accuracy (though it is not as accurate as SLA).
 No post-treatment necessary
 The milling step guarantees that the next layer will be flat.
 Perfect technology for small-scale production runs.

Disadvantages of SGC:

 As the liquid polymer hardens, some wax becomes trapped within the artifact.
 More space is required.
 Cost is on the higher side.
 Elevated operating costs stemming from system intricacy Costly machinery and resources
High operational and upkeep expenses Generates considerable waste.
 Limited selection of materials, specifically photopolymers.

Applications of SGC:
 Models for presentation, packaging, and conception.
 Design, analysis, verification, and functional testing prototypes.
 Wax pattern to be replaced by an investment casting template.
 Prototype and low-volume production tooling masters.
2. Explain the principle, working process, advantages, disadvantages, and
applications of Polyjet.

POLYJET:

Polyjet is a process in which liquid photopolymer resin is sprayed onto a build tray and cured
by ultraviolet light, creating parts layer by layer. Photopolymers, which solidify when
exposed to ultraviolet light, are used in place of ink in this procedure, which is comparable to
inkjet printing. After that, the build platform descends, and the subsequent layer is printed on
top. Printing parts with several colors and materials is possible with multiple print heads.

Fig. Polyjet
Working:
 PolyJet 3D Printing is a cutting-edge technology that uses inkjet heads, UV light, and
photopolymers to rapidly produce exact objects.
 It creates digital materials by layering resins to attain precision.
 A CAD model is first converted into a printable format to begin the process.
 Layers are bonded by jetting photopolymer drops onto the build platform and curing them
with UV lights.
 For the final PolyJet model, support materials are either dissolved or manually deleted.

Advantages of Polyjet:
 Highly Accurate and Detailed Prints
 Wide Range of Materials
 Quick Turnaround Time
 Versatility

Disadvantages of Polyjet:
 Limited Build Volume
 Cost
 Limited Material Options
 Post-Processing Required for Some Applications.

Applications of Polyjet:
 PolyJet technology is used in the automotive industry to produce both functional and
aesthetically pleasing prototypes of various elements, including engine parts, external
body pieces, and interior components.
 For the medical field, PolyJet 3D printing technology offers a number of advantages. To
help with the planning of complicated surgeries, hospitals employ PolyJet 3D printers to
produce customized anatomical models.
 PolyJet technology is utilized in the consumer products sector for a variety of tasks,
including designing packaging, testing and assembly fixtures, pre-production product
photography and videography, and producing fully functional and realistic prototypes.
 PolyJet is revolutionary for injection molding applications because it provides an
economical and effective method of producing short-run molds. Manufacturers may
quickly and affordably evaluate a part's form, fit, and actual function by using PolyJet
molds.
3. Explain the principle, working process, advantages, disadvantages, and
applications of Laminated Object Manufacturing (LOM), Fused
Deposition Modeling (FDM) and Multi Jet Modeling (MJM).

Laminated Object Manufacturing (LOM):

Using a 3D printing technique called Laminated Object Manufacturing (LOM), physical
things are created by stacking sheets of material—usually paper or plastic—and then cutting
each layer into the appropriate shape. After that, heat and pressure are used to glue or join
these layers together. The procedure can be completed economically and is especially helpful
for producing large-scale models and prototypes.

Fig. Laminated Object Manufacturing (LOM)

Working:
An outline of the cross-sectional shape of a CAD model that has been divided into layers is
created by stacking layers of sheet stock to create a solid physical representation.
 Paper, plastic, cellulose, metals, and fiber-reinforced materials are examples of starting
sheet stock.
 Typically, the sheet comes in rolls with an adhesive backing that are spooled between two
reels.
 Excess material in the layer stays in situ after cutting to support the part while it is being
built.
Advantages of Laminated Object Manufacturing:
 Ability to produce larger-scaled models
 Uses very inexpensive paper
 Fast and accurate
 Good handling strength
 Environmentally friendly
 Not health threatening

Disadvantages of Laminated Object Manufacturing:

 Need for decubing, which requires a lot of labor.
 Can be a fire hazard.
 Finish, accuracy and stability of paper objects not as good as materials used with other
RP methods.
Applications of Laminated Object Manufacturing:
 Study models of human organs such as bones, skulls, etc.
 Create the patterns for rubber molding, investment casting, and sand casting.
 Create a very realistic prototype for marketing.
 Create working models in a low-stress setting.

Fused Deposition Modeling (FDM):

A common 3D printing method called fused deposition modeling (FDM) builds a 3D object
layer by layer by melting thermoplastic filament and extruding it via a nozzle. It's an
economical and adaptable technique that's frequently utilized for functional part creation and
prototyping.
 Fig. Fused Deposition Modeling

Working of Fused Deposition Modeling:

According to the specified CAD model, FDM technology uses thermoplastic filaments as the
build input material, which are liquefied and then re-solidified into the required shape. Two
spools make up an FDM printer: one for the build material and one for the support material.
The following are the primary processes in the fused deposition modeling 3D printing
process:
 The liquefier head uses heat to liquefy the solid construction material filament that has
already been loaded after the CAD data has been entered.
 The extrusion nozzle, which travels in all directions specified in the CAD data, feeds the
layer of molten liquid plastic onto the foam construction platform. Repeatedly, the
liquid/semi-solid layers are added one on top of the other.
 Support structures are employed when the design includes overhangs or other elements
that could bend or warp. Depending on the option, the support material may be the same
as the build material or any different material.
 If support structures were utilized, they are subsequently eliminated after the build is
finished.
Advantages of Fused Deposition Modeling:
 FDM Technology Is Affordable
 FDM Works With Many Materials
 FDM Models Can Be Very Detailed
 FDM Filaments Aren’t Easily Contaminated
 Can Print Large Builds
 Fused Deposition Modeling Is Easy
Disadvantages of Fused Deposition Modeling:
 Limited Detail
 Quality Isn’t Perfect
 Lack Of Structural Integrity
 Need Support Structures
 FDM Printers May Intimidate New Users

Applications of Fused Deposition Modeling:

 Durable FDM materials provide a quicker and more cost-effective method of producing
necessary industrial tools.
 Functional prototyping is a fundamental FDM application because of its ease of usage
and long-lasting print outputs.
 A quicker option to traditionally manufactured composite tooling is provided by high-
performance FDM polymers.
 Low-volume and out-of-production spare parts are now economically viable thanks to
FDM technology.

Multi Jet Modeling (MJM):

Multi Jet Modelling (MJM), also known as Polyjet 3D printing, applies tiny material droplets
onto a printing plate using a print head with several nozzles. The desired components can be
created layer by layer since UV light instantly hardens the liquid polymer. The tiny droplets
that are applied allow for the reproduction of extremely fine features. In addition, the
substance melts before curing, leaving a remarkably smooth surface. Support structures for
overhanging components must be included during printing.
 Fig. Multi Jet Modeling

Working of Multi Jet Modeling:

 Liquid acrylic polymers are placed onto a build platform with a printhead that has one or
more nozzles in PolyJet or MultiJet Modeling (PJM/MJM), and they are cured by
exposure to UV light.
 Throughout the procedure, the printhead travels along pathways predetermined by a CAD
model over the platform until a layer is fully produced.
 The plastic is immediately cured by the UV lights, which are situated right on the
printhead.
 A stable link between the stacked layers is achieved by adjusting the UV light's strength
so that the topmost layer does not cure entirely.
 The UV lights go over the entire component multiple times to finish curing once the last
level has been printed.

Advantages of Multi Jet Modeling:

 High construction speed

 Process produces high density and low porosity components
 Ideal for the fast production of prototypes with functional and mechanical properties
 Full-colour component manufacturing possible
Disadvantages of Multi Jet Modeling:

 Limited heat resistance

 High manufacturing costs
 Support structure requirements

Applications of Multi Jet Modeling:

 MJM excels at producing intricate and intricate prototypes for functional testing and
design assessment.
 For form and fit analysis, MJM is able to create working prototypes.
 MJM's high-detail models can serve as masters for castings made with techniques like
vacuum casting.
 Transparent materials are among the materials that MJM can print parts in.
 The technique can also result in sculptures with material and color gradients because it
applies tiny droplets.

UNIT-3

1. Explain the principle, working process, advantages, disadvantages, and

applications of Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS):

The additive manufacturing (AM) process known as selective laser sintering (SLS) uses a
laser as the heat source and power source to sinter powdered material, usually nylon or
polyamide. The laser is automatically aimed at specific locations in space specified by a
three-dimensional (3D) model, binding the material together to form a solid structure.

Working of Selective Laser Sintering:

 Each layer in SLS is drawn into a bed of powder, often nylon, by a high-power laser. The
powder particles are fused together by the laser to create solid structures.
 After a layer is finished, a powder recoater applies fresh powder to the top layer while the
build plate slightly lowers. With layer thicknesses usually falling between 50 and 200
microns, this technology is extremely accurate.
 The machine operator is responsible for removing and de-powdering the prints after they
are finished.
 Another benefit of SLS is that the majority of the leftover powder may be recycled by
combining it with new powder. Printing as many pieces as can fit in the chamber at once,
however, is more efficient.

Fig. Selective Laser Sintering

Advantages of Selective Laser Sintering:

 No support structures
 High productivity
 Excellent mechanical properties
 Ideal for dying and coloring
 Reduced product development time
Disadvantages of Selective Laser Sintering:

 Fewer materials
 Rough surface and porosity
 High shrink rate
 Higher waste than other additive manufacturing

Applications of Selective Laser Sintering:

 Because SLS technology can quickly create complex geometries with little to no
additional production effort, it is widely used in numerous sectors worldwide.
 Early in the design cycle, it is most frequently used in prototype parts, such as wind
tunnel models, automobile hardware, and investment casting patterns.
 Additionally, SLS is being utilized more and more in limited-run production to create
final components for electronics, medical, pharmaceutical, military, and aerospace
hardware.
 SLS can be utilized on a shop floor to quickly manufacture fixtures, jigs, and tooling.

2. Explain the principle, working process, advantages, disadvantages, and

applications of 3 Dimensional Printing.

Three Dimensional Printing:

The method of creating three-dimensional items from a digital file is known as additive
manufacturing or 3D printing. Additive methods are used in the production of 3D printed
objects. In an additive process, material is applied in consecutive layers until the desired
result is achieved. A finely sliced cross-section of the object may be viewed in each of these
levels. However, there is one exception, and that is volumetric 3D printing. Instead of
fabricating structures layer by layer, volumetric printing allows for the simultaneous
formation of whole structures. However, it's important to remember that volumetric
technology is currently mostly in the research stage.
 Fig. 3D Printing
Working of 3D Printing:
 Using computer-aided design (CAD) software, a 3D model of the product is first created.
Layers of the model are cut apart.
 Depending on the printing process being used, the 3D printer is filled with the necessary
raw materials, such as plastic filament, resin, metal powder, etc.
 A 3D printer doesn't use liquid ink or solid powder like inkjet and laser printers do. It
employs adhesives or UV light to fuse layers of molten plastic, metal wire, or powder
with the preexisting structure.
 In accordance with the design file, the 3D printer applies and joins materials layer by
layer. Until the object is formed, the build platform descends and the procedure is
repeated.
 Additional procedures including cleaning, smoothing, baking, and polishing could be
needed for printed items. Structures of support are eliminated.
 Printed items are examined for correctness in dimensions and adherence to design
guidelines. It could be necessary to reprint any errors.
Advantages of 3D Printing:
 3D Printing saves time and money
 3D Printing allows for more efficient testing
 3D Printing produces less waste

Disadvantages of 3D Printing:
 3D Printing equipment is expensive
 The Printer limits the size of your prints
 3D Printing still requires post processing

Applications of 3D Printing:
 To cut down on weight and material requirements, lightweight printed parts can be used
in place of conventionally manufactured parts for airplanes and spacecraft.
 3D printing is used in the automotive sector to create specialized parts and tools as well
as for quick prototyping. Printed components can lighten weight and enhance design.
 Using concrete and other materials, 3D printing technology is being utilized to create full-
size houses and other structures, as well as scale replicas of buildings and bridges.
 With the use of medications, implants, customized prosthetics, and anatomical models for
surgical practice, 3D printing is transforming the healthcare industry.