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Minimizing Build Time and Surface Inaccuracy of Direct Metal Laser Sintered Parts: An Artificial Intelligence Based Optimization Approach

Verma, Anoop P.
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1249840383

Abstract Details

2009, MS, University of Cincinnati, Engineering : Mechanical Engineering.
Direct Metal Laser Sintering (DMLS) is a Rapid Manufacturing (RM) process that can be classified under the area of layered manufacturing techniques, where parts are built in layers. Parts of any complexity can be built directly from the 3D CAD model without much human intervention and requires minimum post-processing. Due to inherent nature of the layering process, staircasing effect is more prominent thus leading to poor accuracy of the fabricated parts. Most of the work done in this area uses adaptive slicing techniques to convert the whole part into layers of varying thickness while keeping track of part features. In general, parts build with thinner layers will always yield better accuracy but will take longer build time. Typically, parts built with thicker layers can be fabricated in a minimum amount of time, but at the expense of poor accuracy. The current work uses a multi-objective approach to minimize the part build time and maximize the surface accuracy. Volumetric error has been used as a metric to determine the part accuracy as minimum volumetric error will generate high accuracy parts. Due to complex nature of the process, an artificial intelligence based search technique, namely, genetic algorithm has been used as the optimization tool to obtain minimum build time and minimum volumetric error. Taking into account the role of part height and laser sintering movement for estimating build time and volumetric error, a constrained minimization technique has been used for efficient part orientation and efficient laser movement to sinter the layered part. The overall optimization of the DMLS process proceeds sequentially from part orientation to laser path planning to finally calculating layer thickness for minimum build time and minimum volumetric error.
Sam Anand, PhD (Committee Chair)
Ronald Huston, PhD (Committee Member)
Manish Kumar, PhD (Committee Member)
86 p.
Mechanical Engineering
Direct Metal Laser Sintering; Volumetric Error; Optimization; Genetic Algorithm; .STL

Recommended Citations

Citations

  • Verma, A. P. (2009). Minimizing Build Time and Surface Inaccuracy of Direct Metal Laser Sintered Parts: An Artificial Intelligence Based Optimization Approach [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1249840383

    APA Style (7th edition)

  • Verma, Anoop. Minimizing Build Time and Surface Inaccuracy of Direct Metal Laser Sintered Parts: An Artificial Intelligence Based Optimization Approach. 2009. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1249840383.

    MLA Style (8th edition)

  • Verma, Anoop. "Minimizing Build Time and Surface Inaccuracy of Direct Metal Laser Sintered Parts: An Artificial Intelligence Based Optimization Approach." Master's thesis, University of Cincinnati, 2009. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1249840383

    Chicago Manual of Style (17th edition)

ucin1249840383
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© 2009, all rights reserved.
This open access ETD is published by University of Cincinnati and OhioLINK.