Abstract
This chapter explores transformation of a virtually produced gear to a physical product using rapid prototyping technique. The same can be segregated into two parts. The first being selection of the best possible rapid prototyping technique using dynamic mechanical analysis and the next was optimization of the process parameters of the selected rapid prototyping technique considering tensile strength as the criteria. The results indicated that fused deposition modeling process provides the best solution amongst the techniques studied. Moreover, as orientation of the product in rapid prototyping techniques plays an important role in providing the strength and also accuracy of the product profile, from results it was also ascertained that strength and profile accuracy of the product was optimized with horizontal position.
TopDifferent Rp Processes
Various RP processes have been developed and also being developed in order to improve the realization of a virtual product to the extent possible. In this case as the product to be produced is of a non-metallic material hence out of all the RP techniques available only Stereolithography (SL), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM) and Laminated Object Manufacturing (LOM) have been studied.
Key Terms in this Chapter
Rapid Prototyping: The process of making physical prototypes for scale down physical model obtained from CAD data.
Selective Laser Sintering: An additive manufacturing technique in which high-power laser source is used to fuse the powdered material to obtain three dimensional physical prototypes.
Part Orientation: The inclination of the being built with respect to the X, Y, and Z axes of a RP machine.
Laminated Object Manufacturing: A rapid prototyping technique where a part is built from layers of papers.
Dynamic Mechanical Analysis: A technique to study the viscoelastic nature of materials especially polymers. The applied stress is sinusoidal in nature and is usually accompanied with varying temperature and frequency.
Fused Deposition Modeling: An additive manufacturing process that builds a part from thermoplastic filament by extruding and heating the filament.
Tensile Modulus: The ability of material to withstand change in length when under tension.
Layer Thickness: The thickness of the layer deposited by the nozzle for creating the solid.
Model Interior: The type of fill to be used for the part (i.e., sparse or solid).
Ultimate Tensile Stress: The maximum stress a material can sustain while being stretched before breaking.
Stereolithography: One of the 3D printing techniques of producing prototypes by converting liquid plastics to solid plastics.
Ultimate Tensile Strain: The strain at the point of failure.