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The Octoball: an artefact for additive manufacturing precision assessment

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(1)Titre: The Octoball: an artefact for additive manufacturing precision Title: assessment Auteurs: Ian Basta, René Mayer et Luc Baron Authors: Date: 2016 Type: Communication de conférence / Conference or workshop item Basta, I., Mayer, R. & Baron, L. (2016, février). The Octoball: an artefact for. Référence: additive manufacturing precision assessment. Dans International Academy for Citation: Production Engineering (CIRP) Winter Meeting, STC-P Meeting, Paris, France (41 pages).. Document en libre accès dans PolyPublie Open Access document in PolyPublie. URL de PolyPublie: PolyPublie URL:. Version:. https://publications.polymtl.ca/5319/ Autre / Other Non révisé par les pairs / Unrefereed. Conditions d’utilisation: Tous droits réservés / All rights reserved Terms of Use:. Document publié chez l’éditeur officiel Document issued by the official publisher Nom de la conférence: International Academy for Production Engineering (CIRP) Winter Conference Name: Meeting, STC-P Meeting Date et lieu: Date and Location:. Maison d’édition: Publisher:. 2016-02-17, Paris, France CIRP. URL officiel: Official URL:. Mention légale: Legal notice: Ce fichier a été téléchargé à partir de PolyPublie, le dépôt institutionnel de Polytechnique Montréal This file has been downloaded from PolyPublie, the institutional repository of Polytechnique Montréal http://publications.polymtl.ca.

(2) International Academy for Production Engineering Winter Meeting – Paris, February 17, 2016. The Octoball – an artefact for additive manufacturing precision assessment. by Ian Basta, J.R.R. Mayer, Luc Baron Presenting author: J.R.R. Mayer, Department of Mechanical Engineering, Polytechnique Montréal, Canada. Email: rene.mayer@polymtl.ca STC P CIRP office: 9 rue Mayran, 75009 PARIS – France, E mail: cirp@cirp.net, http://www.cirp.net.

(3) Literature Review —. Keynote: Kruth, J. P. (1991). "Material Incress Manufacturing by Rapid Prototyping Techniques." CIRP Annals - Manufacturing Technology 40(2): 603614.. —. Childs, T. H. C. and N. P. Juster (1994). "Linear and Geometric Accuracies from Layer Manufacturing." CIRP Annals - Manufacturing Technology 43(1): 163166. (FDM: 0.254 mm). —. Ippolito, R., L. Iuliano and A. Gatto, "Benchmarking of Rapid Prototyping Techniques in Terms of Dimensional Accuracy and Surface Finish." CIRP Annals - Manufacturing Technology 44(1): 157-160, 1995.. —. D. Dimitrov, W. van Wijck, K. Schreve, N. de Beer, and J. Meljer, "An Investigation of the Capability Profile of the Three Dimensional Printing Process with an Emphasis on the Achievable Accuracy," CIRP Annals - Manufacturing Technology, 52(1): 189-192, 2003.. —. C. Bayley1, L. Bochmann, C. Hurlbut, M. Helu, R. Transchel, and D. Dornfeld, "Understanding Error Generation in Fused Deposition Modeling," in 2014 Spring Topical Meeting, ASPE, Volume 57 , 98-103.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 2.

(4) The process : fused deposition modelling (FDM). Keynote: Kruth, J. P. (1991). "Material Incress Manufacturing by Rapid Prototyping Techniques." CIRP Annals - Manufacturing Technology 40(2): 603-614.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 3.

(5) The FDM machines. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 4.

(6) The lab : fused deposition modelling. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 5.

(7) Objective. — Simple measurement and analysis — Quantify the effect of : — Feature position and orientation. — on: — Form; — Size; — Position.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 6.

(8) The artefact design evolution. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 7.

(9) Measurement 5 6. 2. 8 7. 4 3. LEGEX+TP7M Stylus tip φ = 2 mm. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 8.

(10) Measurement; higher density. Low density (19 points). High density (193 points). ISO 10360-2. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 9.

(11) Sphericity of spheres; low and high density. P. Bourdet, A. Clément, Controlling a complex surface with a 3-axis measuring machine, Annals of the CIRP, 25(1), 359-361, 1976.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 10.

(12) Size of spheres; low and high density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 11.

(13) Difference from nominal; shape + size; HD. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 12.

(14) Position of spheres; low and high density low density. low density. high density. high density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 13.

(15) Position of spheres; low and high density. High density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 14.

(16) Norm of spheres position error. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 15.

(17) Discussion; future work — Stylus tip radius? — Separating surface finish and form? — Sampling density? — Fixturing? — Choice of datum features (ABC)? — Optical scanners? — …. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 16.

(18) Acknowledgment Funded by the Natural Sciences and Engineering Research Council of Canada (NSERC). Winter Annual Meeting, Paris. Basta, Mayer, Baron. 17.

(19) The End. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 18.

(20) Bore results – red (machine 2) model. Nominal diameter=52.710 Size error: -0.072 Cylindricity error: 0.259 Winter Annual Meeting, Paris. Basta, Mayer, Baron. 19.

(21) The procedure — Two machine models tested; — Full factorial experiment of. effect of xyz sphere position on positional error Factor. Winter Annual Meeting, Paris. Experiment. X. Y. Z. 1. −. −. −. 2. +. −. −. 3. −. +. −. 4. +. +. −. 5. −. −. +. 6. +. −. +. 7. −. +. +. 8. +. +. +. Basta, Mayer, Baron. 20.

(22) Contents. — FDM — The artefact — The procedure — Some results. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 21.

(23) Printing parameters. Parameters. Value. Layer thickness (wire φ=1.75). 0.15 mm. Orientation of internal structures Thickness of solid supports Spacing of non solid supports. 45 degrees 3 wires 8 lines. Parameters. Value. Filling type. Thickness of skin Maximum slope of ceilings without support Maximum area of holes without support. 4 wires 30° 3 mm2. • ABS (Acrylonitrile Butadiène Styrène) • Wire diameter :. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 22.

(24) Position of spheres; low and high density low density. Ok checked low density. Ok checked. high density. high density Ok checked. Ok checked. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 23.

(25) Difference from nominal; shape + size; LD. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 24.

(26) Difference from nominal; shape + size; HD — HD data. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 25.

(27) Abstract — An artefact made of eight 20 mm radii hemispheres. located at the apices of a rectangular parallelipiped and held together by a single cylindrical core is proposed to study the dimensional and geometric performance of a fused deposition modeling (FDM) process. Two replicas are produced on two different machines and measured on a coordinate measuring machines for sphericity, radius and position. The hemisphere allows a gradual change in the vertical angle of the wall which challenges the process. Results differ for the two machines. Form, size and position errors of the order of XX, XX and XX respectively are obtained for machine 1 and XX, XX and XX for machine 2. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 26.

(28) Sphericity of spheres; low and high density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 27.

(29) Size of spheres; low and high density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 28.

(30) Sphericity of spheres; low density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 29.

(31) Size of spheres; low density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 30.

(32) Position of spheres; low density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 31.

(33) Difference from nominal; shape and size. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 32.

(34) Sphericity of spheres; high density Sphericity error. (mm) 0,6. Machine 1. 0,5. Machine 2. 0,4 0,3 0,2 0,1 0 1. 2. 3. 4. Ball identifier. Winter Annual Meeting, Paris. 5. 6. 7. 8. Basta, Mayer, Baron. 33.

(35) Size of spheres; high density. Radius size error. (mm). Machine 1. 0,02 0 -0,02 -0,04. Machine 2 1. 2. 3. 4. 5. Ball identifier. 6. 7. 8. -0,06 -0,08 -0,1 -0,12. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 34.

(36) Position of spheres; high density. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 35.

(37) Difference from nominal; shape and size — HD data. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 36.

(38) Literature review —. Childs, T. H. C. and N. P. Juster (1994). "Linear and Geometric Accuracies from Layer Manufacturing." CIRP Annals - Manufacturing Technology 43(1): 163-166. (FDM: 0.254 mm) —. No balls.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 37.

(39) Literature review —. Keynote: Kruth, J. P. (1991). "Material Incress Manufacturing by Rapid Prototyping Techniques." CIRP Annals - Manufacturing Technology 40(2): 603-614.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 38.

(40) Literature review —. Ippolito, R., L. Iuliano and A. Gatto, "Benchmarking of Rapid Prototyping Techniques in Terms of Dimensional Accuracy and Surface Finish." CIRP Annals - Manufacturing Technology 44(1): 157-160, 1995.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 39.

(41) Literature review —. D. Dimitrov, W. van Wijck, K. Schreve, N. de Beer, and J. Meljer, "An Investigation of the Capability Profile of the Three Dimensional Printing Process with an Emphasis on the Achievable Accuracy," CIRP Annals - Manufacturing Technology, 52(1): 189-192, 2003.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 40.

(42) Literature review —. L. B. Cindy Bayley, Colin Hurlbut, Moneer Helu, and D. D. Robert Transchel, "Understanding Error Generation in Fused Deposition Modeling," in 2014 SPRING TOPICAL MEETING VOLUME, 98-103.. Winter Annual Meeting, Paris. Basta, Mayer, Baron. 41.

(43)

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