Machine Tools And Devices For Special Technologies

1. Slovak University of Technology Faculty of Material Science and Technology in Trnava Machine Tools And Devices For Special Technologies Rapid Prototyping

2. Rapid prototyping • Based on the creating and using of virtual space numerical model of the designed product. • Possibility of straight production of the designed product model eventually of final product on the base of 3D data transport from CAD system to Rapid Prototyping system.

3. Prototype • First material visualisation of the workpiece and it is for the next processing of workpiece design necessary. • Gets: • Practical information about function, quality of product and about costs for his producing.

4. Prototyping We can divided it into several groups: • Mock – up – prototype gives to user the view how it approximately look, • Bread-board – prototype is using but yet has not created users border line, • Scale model – has users border line but supported only parts of all conditions, • Concept – car – where the prototype is generated to assignment of market price, • Simulation – where the prototype extracts screenplay and conception of user, • Characteristic model – formally specification of system, • Blue-print – definition how to do really system implementation, • Effectible Blue-Print -descriptionhow to do real implementation that is output simulations

5. Advantage of Rapid Prototyping • In addition to possibility of fast model production, patterns and prototype but mainly production possibility of final lines of modifications and constructed settings of designed product.

6. Creating of 3D workpiece model makes possible to: • Fast creating of complex shape geometry and workpiece dimension that are expressly described and teamed in screen of monitor • Automatic of cut creating and views to machined workpiece, • Create and verify other constructional variants of workpieces, • Simulated in the space of screen the kinematics it means movements of particular parts of designed machine tool and to verify possibility of collision becoming, • Realised study of built up the area and assembly kind of workpiece or machine tool • Used generated data for Rapid Prototyping, • To set up the programs for machine tool controlling, • Simulated the process of workpiece machining in the screen, include motions optimalization of tool and design of optimal cutting conditions. • Design of the casts up, fixtures and tools for workpiece production.

7. Rapid Prototyping • Mutual aspect of these Rapid Prototyping methods is that workpiece creating is realised of layer to layer. • Is possible to produce shape difficult workpieces with : • hollow inside spaces, • Horizontal and diagonal surface, • Ribs in the very short time.

8. Model design for Rapid prototyping

9. Methods of Rapid Prototyping • Stereo lithography (Sl) • Solid Ground Curing (SGC) • Selective Laser Sintering (SLS) • Fused Deposition Modelling (FDM) • Laminated Object Manufacturing (LOM) • Direct Shell Production Casting (DSPC) • Model Market 3D Plotting and Ballistic Particle Manufacturing (BMP) Multi Jet Modelling

10. Stereo lithography (SL) It is producing of the workpiece realised layer to layer by hardening of the liquid photopolymer by UV laser (photo polymerization). On the base of created information about shapes and dimensions are enumerated operated datas that supported the laser beam by XY scanning head.

11. Stereo lithography (SL) • Laser • Processing head of laser • System for moving of support desk • Support desk • Processing pool • CNC operated system • Photopolymer • Support • Machined workpiece

12. Solid Ground Curing (SGC) Producing proceeding of models based on the photo polymerization where is rim lighted through mask by UV lamp. This method makes possible to create rangy and shape difficult prototype workpieces.

13. Solid Ground Curing (SGC) Advantages: • In the SGC process is not needed making stronger, • Complication of creating workpieces has not influence to the time for their production • Process of production are not dependenced, • Damages layers can be after detecting immediately milled. • Can be produce synchronize more prototype workpieces.

14. Solid Ground Curing (SGC) • Used polymers are relatively expensive, • Production devices are very large, noisy and expensive for maintenance, • Necessity to remove the wax after workpiece creating. • Little selection of using input materials for prototype components.

15. Selective Laser Sintering (SLS) Method based on the principle of the local sintering, eventually melting of powder materials by influence of laser beam. Used the components of thermoplastic materials, special low melting metal alloys of nickel bronze and of polymers coated powder.

16. Selective Laser Sintering (SLS) Advantages: • Cheap and no harmed healthy material, • Large selection of used materials, • Is not needed supported construction, • Decreasing of destruction possibility of inside stresses.

17. Selective Laser Sintering (SLS) Disadvantages: Roughness surface after final modification it means „stairs“ effect, Porosity of components, Different intensity in various parts of generated components, Material transformations are needing cleaning of the production device

18. Selective Laser Sintering (SLS) – functional scheme

19. Device for Selective Laser Sintering (SLS) EOSINT P 360

20. Fused Deposition Modelling (FDM) Component is processing by step to step layering of material that is outgoing of heated jet.

21. Principle of FDM method

22. Laminated Object Manufacturing Method based on the shape cutting by lasers of special foils and of their gradually layering by sticking. By this method is possible to produce quantity of components eventually fast because they has scanning only their contours

23. Principle of Laminated Object Manufacturing

24. Direct Shell Production Casting Principle of this method is like the same as in the method of Selective Laser Sintering. Base material like powder is sticking by liquid binding material. With this method is possible to generated of ceramic powder various components, forms and casts for processes of straight casting.

25. Model Market 3D plotting and Ballistic Particle Manufacturing Material coating is like that drops of material (thermoplast) are darted to process surface and after impact are hardened.

26. Model Market 3D plotting Method that work with two pressure jets, the first coating material and second shaped it. Method Ballistic Particle Manufacturing Method process only with one pressure head that has five degree of celsius.