Tugdual Amaury Le Néel, Pascal Mognol and Jean-Yves Hascoët
The purpose of this paper is to analyze the current state of the art manufacturing techniques using sand molds for the casting industry by the means of additive manufacturing…
Abstract
Purpose
The purpose of this paper is to analyze the current state of the art manufacturing techniques using sand molds for the casting industry by the means of additive manufacturing (AM). In particular, this review will cover two families of 3D printing in regards to sand mold fabrication.
Design/methodology/approach
This paper will discuss the sand casting manufacturing processes of AM by binder jetting (3D printing) and selective laser sintering. Scientific articles, patents and case studies are analyzed. Topics ranging from the technology types to the economic implications are covered.
Findings
The review investigates new factors and methods for mold design, looking at mechanical properties and cost analysis as influenced by material selection, thermal characteristics, topological optimization and manufacturing procedure. Findings in this study suggest that this topic lacks vigorous scientific research and that the case studies by manufacturers thus far are not useful.
Research limitations/implications
As demonstrated by the limited data from previous published studies, a more comprehensive and conclusive analysis is needed due to the lack of interest and resources regarding the AM of sand molds.
Practical implications
This study is a useful tool for any researchers with an interest in the field of AM of sand molds.
Social implications
Key perspectives are proposed.
Originality/value
This review highlights current gaps in this field. The review goes beyond the scientific articles by curating patents and professional case studies.
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Benoit Rosa, Pascal Mognol and Jean-Yves Hascoët
Direct metal deposition (DMD) with laser is an additive manufacturing process enabling rapid manufacturing of complex metallic and thin parts. However, the final quality of…
Abstract
Purpose
Direct metal deposition (DMD) with laser is an additive manufacturing process enabling rapid manufacturing of complex metallic and thin parts. However, the final quality of DMD-manufactured surfaces is a real issue that would require a polishing operation. Polishing processes are usually based on abrasive or chemical techniques. These conventional processes are composed by many drawbacks such as accessibility of complex shapes, environmental impacts, high time consumption and cost, health risks for operators, etc. […] This paper aims to solve these problems and improve surface quality by investigating the laser polishing (LP) process.
Design/methodology/approach
Based on melting material by laser, the LP process enables the smoothing of initial topography. However, the DMD process and the LP processes are based on laser technology. In this context, the laser DMD process is used directly on the same machine for the polishing operation. Currently, few studies focus on LP of additive laser manufacturing surfaces, and it tends to limit the industrial use of additive manufacturing technology. The proposed study describes an experimental analysis of LP surfaces obtained by DMD process.
Findings
The investigation results in the improvement of a complete final surface quality, according to LP parameters. For mastering LP processes, operating parameters are modelled.
Originality/value
This experimental study introduces the LP of thin and complex DMD parts, to develop LP applications. The final objective is to create a LP methodology for optimizing the final topography and productivity time according to parts’ characteristics.
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Pierre Muller, Jean-Yves Hascoet and Pascal Mognol
The purpose of this paper is to propose an evaluation of toolpaths for additive manufacturing of functionally graded materials (FGM) parts to ensure the manufacturing of parts in…
Abstract
Purpose
The purpose of this paper is to propose an evaluation of toolpaths for additive manufacturing of functionally graded materials (FGM) parts to ensure the manufacturing of parts in compliance with the desired material distribution. The selection of an appropriate path strategy is critical when manufacturing FGM parts.
Design/methodology/approach
The selection of a path strategy is based on a process modeling and an additive laser melting (ALM) system control. To do that, some path strategies are selected, simulated and compared.
Findings
The comparison of some paths strategies was applied on a study case from the biomedical field. Test-parts were manufactured and analyzed. Results show a good correlation between the simulated and the deposited material distributions. The evaluation of toolpaths based on the process modeling and the system control was validated.
Originality/value
Nowadays, FGM parts manufactured with ALM processes are not functional. To move from these samples to functional parts, it is necessary to have a global approach of the manufacturing procedure centered on the path planning. Few methodologies of path planning are adapted to FGM parts but are still limited.
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Olivier Kerbrat, Pascal Mognol and Jean‐Yves Hascoet
The purpose of this paper is to propose a methodology to estimate manufacturing complexity for both machining and layered manufacturing. The goal is to take into account…
Abstract
Purpose
The purpose of this paper is to propose a methodology to estimate manufacturing complexity for both machining and layered manufacturing. The goal is to take into account manufacturing constraints at design stage in order to realize tools (dies and molds) by a combination of a subtractive process (high‐speed machining) and an additive process (selective laser sintering).
Design/methodology/approach
Manufacturability indexes are defined and calculated from the tool computer‐aided design (CAD) model, according to geometric, material and specification information. The indexes are divided into two categories: global and local. For local indexes, a decomposition of the tool CAD model is used, based on an octree decomposition algorithm and a map of manufacturing complexity is obtained.
Findings
The manufacturability indexes values provide a well‐detailed view of which areas of the tool may advantageously be machined or manufactured by an additive process.
Originality/value
Nowadays, layered manufacturing processes are coming to maturity, but there is still no way to compare these new processes with traditional ones (like machining) at the early design stage. In this paper, a new methodology is proposed to combine additive and subtractive processes, for tooling design and manufacturing. A manufacturability analysis is based on an octree decomposition, with calculation of manufacturing complexity indexes from the tool CAD model.
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Zhicheng Huang, Jean-Yves Dantan, Alain Etienne, Mickaël Rivette and Nicolas Bonnet
One major problem preventing further application and benefits from additive manufacturing (AM) nowadays is that AM build parts always end up with poor geometrical quality. To help…
Abstract
Purpose
One major problem preventing further application and benefits from additive manufacturing (AM) nowadays is that AM build parts always end up with poor geometrical quality. To help improving geometrical quality for AM, this study aims to propose geometrical deviation identification and prediction method for AM, which could be used for identifying the factors, forms and values of geometrical deviation of AM parts.
Design/methodology/approach
This paper applied the skin model-based modal decomposition approach to describe the geometrical deviations of AM and decompose them into different defect modes. On that basis, the approach to propose and extend defect modes was developed. Identification and prediction of the geometrical deviations were then carried out with this method. Finally, a case study with cylinders manufactured by fused deposition modeling was introduced. Two coordinate measuring machine (CMM) machines with different measure methods were used to verify the effectiveness of the methods and modes proposed.
Findings
The case study results with two different CMM machines are very close, which shows that the method and modes proposed by this paper are very effective. Also, the results indicate that the main geometrical defects are caused by the shrinkage and machine inaccuracy-induced errors which have not been studied enough.
Originality/value
This work could be used for identifying and predicting the forms and values of AM geometrical deviation, which could help realize the improvement of AM part geometrical quality in design phase more purposefully.
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Luis Lisandro Lopez Taborda, Heriberto Maury and Jovanny Pacheco
There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to…
Abstract
Purpose
There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to corroborate and deepen other researchers’ findings, dissipate divergences and provide directing to future work on the subject from a methodological and convergent perspective.
Design/methodology/approach
This study analyzes the previous reviews (about 15 reviews) and based on the consensus and the classifications provided by these authors, a significant sample of research is analyzed in the design for additive manufacturing (DFAM) theme (approximately 80 articles until June of 2017 and approximately 280–300 articles until February of 2019) through descriptive statistics, to corroborate and deepen the findings of other researchers.
Findings
Throughout this work, this paper found statistics indicating that the main areas studied are: multiple objective optimizations, execution of the design, general DFAM and DFAM for functional performance. Among the main conclusions: there is a lack of innovation in the products developed with the methodologies, there is a lack of exhaustivity in the methodologies, there are few efforts to include environmental aspects in the methodologies, many of the methods include economic and cost evaluation, but are not very explicit and broad (sustainability evaluation), it is necessary to consider a greater variety of functions, among other conclusions
Originality/value
The novelty in this study is the methodology. It is very objective, comprehensive and quantitative. The starting point is not the case studies nor the qualitative criteria, but the figures and quantities of methodologies. The main contribution of this review article is to guide future work on the subject from a methodological and convergent perspective and this article provides a broad database with articles containing information on many issues to make decisions: design methodology; optimization; processes, selection of parts and materials; cost and product management; mechanical, electrical and thermal properties; health and environmental impact, etc.