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Optimum Part Build Orientation in Additive Manufacturing for Minimizing Part Errors and Build Time

Das, Paramita
http://orcid.org/0000-0002-3823-0149
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1467988134

Abstract Details

2016, MS, University of Cincinnati, Engineering and Applied Science: Mechanical Engineering.
Additive Manufacturing (AM) is a process where an initially conceptualized 3D CAD model is fabricated by adding successive layers of material on top of each other while eliminating the need for any process planning. Metal powder based AM processes are gaining popularity in several industries such as aerospace, health care, architecture, industrial design, automotive and consumer products due to the ease with which complex and intricate parts can be manufactured. However, achieving part quality and meeting the design tolerances is one of the most crucial challenges faced by AM among various others such as minimizing support structures, build time, build cost, energy expenditure and support structures removal. The primary cause for not achieving the design tolerances can be assigned to the staircase effect, which is inevitable in AM processes. The leading factor that affects the staircase error and in turn the part quality is the part build orientation. Apart from part quality, build orientation also influences build time, which is another vital aspect since it directly affects the manufacturing cost of the part. The objective of this thesis is to provide an approach to identify an optimal part build orientation which will satisfy all the Geometric Dimensioning and Tolerancing (GD&T) of the part while minimizing its build time. Siemens PLM NX API is used to extract the GD&T callouts and associated geometric information of the CAD model. This is used later to verify if the design tolerances are met. Next, geometric correlation between build orientation, slice thickness and GD&T errors are established. A non-linear constrained weighted optimization model is also developed to identify the best build orientation for meeting the design tolerances and minimizing part errors along with build time.
Sundararaman Anand, Ph.D. (Committee Chair)
Thomas Richard Huston, Ph.D. (Committee Member)
David Thompson, Ph.D. (Committee Member)
59 p.
Mechanical Engineering
Additive Manufacturing; Part Build Orientation; Build Time; Geometric Tolerances; Optimization; Siemens PLM NX API

Recommended Citations

Citations

  • Das, P. (2016). Optimum Part Build Orientation in Additive Manufacturing for Minimizing Part Errors and Build Time [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1467988134

    APA Style (7th edition)

  • Das, Paramita. Optimum Part Build Orientation in Additive Manufacturing for Minimizing Part Errors and Build Time. 2016. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1467988134.

    MLA Style (8th edition)

  • Das, Paramita. "Optimum Part Build Orientation in Additive Manufacturing for Minimizing Part Errors and Build Time." Master's thesis, University of Cincinnati, 2016. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1467988134

    Chicago Manual of Style (17th edition)

ucin1467988134
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This open access ETD is published by University of Cincinnati and OhioLINK.