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Article
Publication date: 14 May 2018

Abdurahman Mushabab Al-Ahmari, Osama Abdulhameed and Awais Ahmad Khan

In additive manufacturing processes such as stereolithography and fused deposition modeling, optimal part orientation is pivotal in improving the quality of the part. This paper…

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Abstract

Purpose

In additive manufacturing processes such as stereolithography and fused deposition modeling, optimal part orientation is pivotal in improving the quality of the part. This paper aims to propose an automatic and optimal part orientation system to improve part quality/accuracy in additive manufacturing, which minimizes the production time and hence reduces the cost of product.

Design/methodology/approach

The developed system reads STEP AP 203 E2 file from CATIA V5 and generates data extraction output file by extracting the relevant geometrical and topological data using an object-oriented approach. Afterwards, the algorithms and rules are developed to extract and recognize feature faces along with their geometric properties such as face type, face area, parallelism and perpendicularity. The feature data obtained that are used to develop feasible part orientations depend on the maximization of G&DT for all part faces. The automatic slicing is then achieved by creating slicing file using CATVBA editor inside CATIA V5.

Findings

After slicing, output data are exported in Excel data sheet to calculate the total additive volume of the part. The building time of the part is then calculated on the basis of machine parameters, part geometry, part height, layer thickness and amount of support volume needed to build the part. The optimal orientation of the part is achieved by maximization of G&DT value and minimization of production time. The proposed methodology is tested using an illustrative example.

Originality/value

Although lot of approaches have been discussed in the literature, automation of setup planning/orientation of the part in additive manufacturing is not fully attained. Therefore, the article focuses on the automation of setup planning by adding automatic feature extraction and recognition module along with the automatic slicing during setup planning. Moreover, the significance of adding feature extraction and recognition module is to achieve best accuracy for form feature faces and hence reduction in post processing machining/finishing operations.

Details

Rapid Prototyping Journal, vol. 24 no. 4
Type: Research Article
ISSN: 1355-2546

Keywords

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Article
Publication date: 28 September 2018

Osama Abdulhameed, Abdurahman Mushabab Al-Ahmari, Wadea Ameen and Syed Hammad Mian

Hybrid manufacturing technologies combining individual processes can be recognized as one of the most cogent developments in recent times. As a result of integrating additive…

408

Abstract

Purpose

Hybrid manufacturing technologies combining individual processes can be recognized as one of the most cogent developments in recent times. As a result of integrating additive, subtractive and inspection processes within a single system, the relative benefits of each process can be exploited. This collaboration uses the strength of the individual processes, while decreasing the shortcomings and broadening the application areas. Notwithstanding its numerous advantages, the implementation of hybrid technology is typically affected by the limited process planning methods. The process planning methods proficient at effectively using manufacturing sources for hybridization are notably restrictive. Hence, this paper aims to propose a computer-aided process planning system for hybrid additive, subtractive and inspection processes. A dynamic process plan has been developed, wherein an online process control with intelligent and autonomous characteristics, as well as the feedback from the inspection, is utilized.

Design/methodology/approach

In this research, a computer-aided process planning system for hybrid additive, subtractive and inspection process has been proposed. A framework based on the integration of three phases has been designed and implemented. The first phase has been developed for the generation of alternative plans or different scenarios depending on machining parameters, the amount of material to be added and removed in additive and subtractive manufacturing, etc. The primary objective in this phase has been to conduct set-up planning, process selection, process sequencing, selection of machine parameters, etc. The second phase is aimed at the identification of the optimum scenario or plan.

Findings

To accomplish this goal, economic models for additive and subtractive manufacturing were used. The objective of the third phase was to generate a dynamic process plan depending on the inspection feedback. For this purpose, a multi-agent system has been used. The multi-agent system has been used to achieve intelligence and autonomy of different phases.

Practical implications

A case study has been developed to test and validate the proposed algorithm and establish the performance of the proposed system.

Originality/value

The major contribution of this work is the novel dynamic computer-aided process planning system for the hybrid process. This hybrid process is not limited by the shortcomings of the constituent processes in terms of tool accessibility and support volume. It has been established that the hybrid process together with an appropriate computer-aided process plan provides an effective solution to accurately fabricate a variety of complex parts.

Details

Rapid Prototyping Journal, vol. 24 no. 6
Type: Research Article
ISSN: 1355-2546

Keywords

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Article
Publication date: 11 September 2019

Swapnil Vyavahare, Soham Teraiya, Deepak Panghal and Shailendra Kumar

Fused deposition modelling (FDM) is the most economical additive manufacturing technique. The purpose of this paper is to describe a detailed review of this technique. Total 211…

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Abstract

Purpose

Fused deposition modelling (FDM) is the most economical additive manufacturing technique. The purpose of this paper is to describe a detailed review of this technique. Total 211 research papers published during the past 26 years, that is, from the year 1994 to 2019 are critically reviewed. Based on the literature review, research gaps are identified and the scope for future work is discussed.

Design/methodology/approach

Literature review in the domain of FDM is categorized into five sections – (i) process parameter optimization, (ii) environmental factors affecting the quality of printed parts, (iii) post-production finishing techniques to improve quality of parts, (iv) numerical simulation of process and (iv) recent advances in FDM. Summary of major research work in FDM is presented in tabular form.

Findings

Based on literature review, research gaps are identified and scope of future work in FDM along with roadmap is discussed.

Research limitations/implications

In the present paper, literature related to chemical, electric and magnetic properties of FDM parts made up of various filament feedstock materials is not reviewed.

Originality/value

This is a comprehensive literature review in the domain of FDM focused on identifying the direction for future work to enhance the acceptability of FDM printed parts in industries.

Details

Rapid Prototyping Journal, vol. 26 no. 1
Type: Research Article
ISSN: 1355-2546

Keywords

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