softcopy report bengkfafael almost complete 2

1. TITLE

ADVANCE MANUFACTURING ( PRODUCT QUALITY )

2. OBJECTIVEi. To understand machining error

ii. To understand the function of Coordinate Measuring Machine and Rapid Prototyping

Machine

iii. To evaluate the product specimen with the tolerance is (+- 1%)

iv. To understand the process of Rapid Prototyping Machine and Coordinate Measuring

Machine works.

3. INTRODUCTION

Rapid prototype is defined as one of the technologies that used to produce an instant

scale model component that generated from 3D CAD software and then convert to CAM and

then evaluate by Coordinate Measuring Machine where in industry this technology mostly

used in prototype stage which is after the drawing stage.

Drawing

Prototype

Pilot Production

Mass Production

Quality Assurance

advance manufacturing (PRODUCT QUALITY)

The advantages of using rapid prototype machine are include to decrease product

development time, low material waste, higher energy efficiency and to extend the product life

cycle. Nowadays, this machine was applied to some applications such as metal washers, wire

forms, sheet metal fabrications, metal stamping and many more.

4. THEORY

This experiment is mainly about the advance manufacturing, advance manufacturing is a

new process in order to replace old types of manufacturing process and the advantages of

advance manufacturing is its ability to analyse the processed and its failure before it is being

made into 3D object.

Basically there a few important rules that advance manufacturing takes place, the first

thing is about the 3D software.in markets there a many software that use 3D coordinate

system to being able to draw object or visualised object into 3D.This will makes the object

able to do simulation and the object will be able to reconstructed. This huge advantage of 3D

software changes the order of manufacturing industry, in terms of cost of production. This is

because the company will be able to use the 3D software to create a new product and being

able to do simulation and the failure point of each new product are known before the real

product is made. The other advantage of 3D software also is the ability to change its data file

to 2D.This ability will enhance the use of software for many purpose for designer, architect

and engineer. The example of 3D software that have in market are SolidWork, Solid Edge,

Swift 3D and CATIA.


Example of 3D software:

In order to combine all the different working framework for each types of 3D

software, a universal file conversion system is created. This is because when using certain

types of 3D software and u need to open the file in other 3D software the framework is

different. So a universal data file had been created in order to ease the operation. In the

industrial of manufacturing the uses of 3D software is closely related to the Computer Aided

Manufacturing (CAM), in order to standardise the conversion between 3D software and

CAM the .stl (STereoLithography) this file also being called the Standard Tessellation

Language. This file has been created by using complex binary codes in order to being able

the file to be used in many ways.

The consequences of having the 3D software the .stl file comes the new things that

has been called the Rapid Prototyping Machine. This machine allow the visualisation of 3D

object that having 3 axis system to be printed. This machine work exactly like the paper

printer both have ink and mechanism to print onto something. The main difference about

Rapid Prototyping is the ability to print and 3D object layer by layer until the object become

a solid foundation. The limitation of the Rapid Prototyping is the ability to print a 3D object

is limited to only certain material of ink. There are some types of rapid prototyping, the

stereolithography also knows as (SLA) the process is mainly about using the laser to turns

thin layer of liquid plastic into solid. Meanwhile the other types is the Selective Laser

Sintering, this technique is about the laser that will used to turns a powder that will skim the

SolidWork CATIA


powder surface to hardening the surface into desired 3D object that have been created in 3D

software. Next is the Fused Deposition Modelling, this technique is same as the technique of

printing, the material that flow out of the nozzle layer by layer to produce 3D object.

Example of Rapid Prototyping Machines:

There are many material that can be used in Rapid Prototyping Machine. Acrylic is

one types of the material. This material have properties of plasticity but the different is the

amount of elasticity is very low. The ability of this material that can be solidified easily

because of it low melting point become a choice to be the material that suitable to be the ink

of Rapid Prototyping Machine. The material easily moves through the tiny nozzle and printed

Cyrus

3D Printer


layer by layer. But in order to form a rigid solid object other material need to support it

contained the acrylic so it will solidified firmly.

Example of Rapid Prototyping Machine Products:

The use of wax is very suitable because of it behaviour that melt easily and solidified

fast. The use of the wax will help the acrylic to hold the position of the shape until the acrylic

is fully solidified. By using wax the object or product will form a rigid surface also have a

better surface finish. The advantages of using wax also is the ability to removes it from the

surface of product. By heating the wax in the furnace the wax is easily removes because the

melting point is low, so it will not affected the acrylic because acrylic have higher melting

point.

After finishing a product the product quality is important rule that have be

determined. Product quality can be categorized into certain aspect, the performance, features,

reliability, and durability and aesthetics value. All this characteristics is important because the

end user of product will evaluate the product quality of the finishing goods.

In order to have a good product the tolerance also become a role in functionality of

the product. A good tolerance determination will cause the product have a long life durability

and maintained the function. Tolerance is very important and necessarily in moving part and

temperature variable part.

FDM SLA FDM


Beside the tolerances the calibration also is needed in order to daily or monthly or

depends on the use of the product. Calibration will allow the use of the product to precisely

accurate and almost zero calibration error. Example of things that calibration in necessarily is

product that involves measurement.

Lastly, in certain product the roundness of it surface or its physical is needed.

Roundness of an object is the calculation of the diameter sides to almost perfectly having less

or almost zero difference. Things that required roundness of it playing role is such as the

axial of and object, mechanical arm or in car parts.


5. APPARATUS AND INDUSTRIAL APPARATUS

5.1 APPARATUS

Computer

3D Software


Coordinate Measuring Machine

Rapid Prototyping Machine


Specimen Oven

Refrigerator


5.2 INDUSTRIAL APPARATUS

RAPID PROTYPING MACHINE

1. ProX 950

Manufacturer: 3D System Corporation

Specification:

ProX 950Material Support Accura: Xtreme, CeraMax Composite, Peak, CAstPro, ClearVue,

Xtreme White 200, 25Work Space 126 x 220 x 228 cmWeight 150kgData file .stl, .slcAccuracy +/-0.05mm


2. MDX-540

Manufacturer: Roland

Specification:

ProX 540Material Support Plastic, resin, wood and non-ferrous metalsWork Space 500mm x 400mm x 155mmWeight 102kgData file SRP Player, 3D Engrave, Dr.EngraveAccuracy +/- 0.05mm


CENTER MEASURING MACHINE

1. CENTER MAX

Manufacturer: Carl Zeis

Specification:

CENTER MAXSensor VAST(Variable Accuracy and Speed Probing Technology)Accuracy 1.6 + L/3000 µm (L=Measured length)


2. DURAMAX

Manufacturer: Carl Zeis

Specification:

DURAMAXSensor VAST(Variable Accuracy and Speed Probing Technology) XXTAccuracy 2.4 + L/ 00 µm (L=Measured length)


3D RAPID PROTOTYPING

MACHINE

ADVANTAGE LIMITATION

ProX 950 Ultimate Accuracy Better surface finish Support .stl , .slc file

Required special material

High cost of material

MDX-540 Many material supported

Very quick for large prototype product

Cheap material can be used

Low surface finish Required special

software

CENTER MEASURING MACHINE

ADVANTAGE LIMITATION

CENTER MAX Economic Accurate Ergonomics Easy interface Use VAST

1.6 + L/3000 µm (L=Measured length)

DURAMAX Small Use VAST XXT

version Calculation

computerized

2.4 + L/ 00 µm (L=Measured length)


6. PROCEDURE

1. The specimen was drawn into two different shapes at its centre by a 3D software

called Catia Software with the parameters as shown.

20mm

20mm

2. Fonts was crafted on the drawing by these steps in the Catia,

Start – mechanical design – drafting – text ( choose font and size ) – save as ig2

3. The CAD data was saved in a thumb drive and then been transferred to the computer

that connected to the rapid prototype machine.

4. The drawing was confirmed its position to be printed while waiting for the material

which are the wax that coated the acrylic in the printer was checked.

5. A work tray was inserted into the slot in the machine where the specimen will be

drawn on it.

6. The drawing was printed into scale model component for 1 hour and 52 minutes.

7. After the printing was finished, the specimen was kept in the refrigerator for 10

minutes in order to dry the wax that coated the acrylic plastic to ease the removal of

the wax from the acrylic.

8. The specimen was transferred into an oven provided for 15 minutes at 95°C to melt

the wax which are the melting point of the wax is lower than the acrylic.

9. The specimen was then immersed in hot water in order to remove the wax from the

specimen.

10. Finally, it was cleaned by tissue provided for finishing of surface stage of the

specimen.


DATA TABULATION

L3 L3

L4 L2 L4 L2

L1 L1

29 ( 1a ) 29 ( 1b )

SPECIMEN 29 ( 1a ) SPECIMEN 29 ( 1b )

THEORETICAL VALUE

(mm)

EXPERIMENTALVALUE

(mm)

ERROR (%)

THEORETICAL VALUE

(mm)

EXPERIMENTALVALUE

(mm)

ERROR (%)

DIAMETER 50 49.568 0.864 50 49.702 0.596

ROUNDNESS 0.1929 0.1614

L1 (5) 20 19.741 1.295 20 19.803 0.985

L2 (6) 20 19.769 1.155 20 19.761 1.195

L3 (7) 20 19.552 2.240 20 19.810 0.950

L4 (8) 20 19.764 1.180 20 19.735 1.325

Table 1 : Table of percentage errors for each specimen


1 2 3 40

0.5

1

1.5

2

2.5

Graph of Percentage Error of Specimens

Specimen 29 ( 1a ) Specimen 29 ( 1b )

Length of each side

Perc

enta

ge e

rror

Graph 1 : Graph of percentage of errors vs. length


L2

SPECIMEN 29 ( 2b ) SPECIMEN 29 ( 2a )

THEORETICAL VALUE

EXPERIMENTAL VALUE

ERROR ( % )

THEORETICAL VALUE

EXPERIMENTAL VALUE

ERROR ( % )

DIAMETER (mm)

50.000 49.651 0.698 50.000 49.545 0.910

ROUNDNESS 0.152 0.0086

L1 (mm) 20.000 19.509 2.455 20.000 19.752 1.240

L2 (mm) 20.000 19.613 1.935 20.000 19.819 0.905

L3 (mm) 20.000 20.000 0.000 20.000 19.786 1.070

a (deg) 60.000 59.300 1.167 60.000 60.100 -0.167

b (deg) 60.000 58.590 2.350 60.000 59.490 0.850

c (deg) 60.000 61.290 2.150 60.000 60.000 0.000

Table 2 : Table of percentage errors for specimen triangle-shape centre


b b

RESULT ANALYSIS


Percentage Error of Diameter

(Theoretical Value – Experimental Value / Theoretical Value ) x 100

Specimen 29 ( 1a )

= (50 – 49.568 / 50 ) x 100

= 0.864 %

Specimen29 ( 1b )

= (50 – 49.702 / 50 ) x 100

= 0.596 %

Percentage error of each length


Example :

Percentage error of L1

= ( 20 -19.741 / 20 ) x 100

= 1.295 %

Percentage error of angle


Example :

Percentage error of angle (a)

= ( 60° - 59.300 / 60 ) x 100

= 1.167%


DISCUSSION

Based on the measurement that have done, it shown that there were errors happened

while doing the experiment. In this experiment, there was two different shapes at the centre

of the circle. One of it is square and another one is triangle. The value of each error for the

square-shape centre was tabulated in Table 1. From the table shown, the comparison is

between specimen 29 ( 1a ) with specimen 29 ( 1b ). The highest error happened on the

specimen 1a is on length named L3 with the value of percentage of error is 2.240% while the

lowest value is on the L2. On the other hand, specimen 1b have the highest error is on the L4

with the value, 1.325% while the lowest one is on the L3 with the value, 0.950%. These

results was then visualised in the graph 1. From the graph, it can be seen that specimen 1a

gives higher percentage of errors for L1 and L3 compare to specimen 1b. Even though at the

L2 and L4 it was recorded that specimen 1b was higher than specimen 1a but it gave a small

difference of value.

For the triangle-shape centre, the result was tabulated in Table 2 and visualised in

Graph 2. From the table, it shown that for the specimen the highest value of percentage error

of length is on the L1 with the value, 2.455%. Meanwhile, the highest value of percentage

error for angle is on angle c with the value, 61.290 which exceed the theoretical value.

These errors was happened due to a few reasons. The first reason is due to machining

error. Machining error including the inferior dimensional accuracy. Besides that, error in

machining involved on the change in magnitude especially for the triangle-shape centre. It

will affect the angle of the triangle. Other than that, to build a part for different orientation it

needs a number of layers required or the material shrinkage problem during prototyping that

lead to the roundness happened. Thus, from there error would occur. These kind of errors

usually happened in rapid prototype machine. In CMM machine, there was some errors that

occurred too. One of it is the tool tip of the machine is dominated by the motion error or also

called as 21 parametric errors. Due to that problem, reading taken were inaccurate. How the

person in charge control the remote also can affect the reading because error appeared.


CONCLUSION

It can be conclude that in this kind of machine or technology also needs accuracy.

Technology on prototyping is by using Rapid Prototyping Machine or some sort like 3D

Printer and the way to achieve the accuracy is by measure those dimension by using the

appropriate machine such as Coordinate Measuring Machine with the correct method or

process of using it. These two machine somehow relate to each other to meet accuracy. The

tolerance of 1% for the specimens almost achieved except for one to two reading only for

each specimen. There was one side of one specimen that meet the tolerance with 0%. Thus,

objective was achieved.

RECOMMENDATION

I. It is recommended that


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