基于光固化法的嵌套器件的工艺研究

简述了合理添加支撑结构的方法,并分析了成型表面粗糙的原因,提出了提高面型精度和避免飘移的多种措施,为嵌套类复杂器件的光固化加工提供了参考。     

高分辨率激光快速成形系统研究与开发

开发了一种新型激光快速成形系统。利用该系统可制作尺寸范围为65 mm×65 mm×150mm的制件原型。 该系统由He-Cd单模激光器、小光斑扫描系统、新型树脂涂层系统及控制系统组成。由扩束镜、高精度扫描振镜 及f-θ透镜构成扫描系统,扫描面上的激光光斑直径达到0.012 mm。由蠕动泵、高精度工作台、树脂槽及刮刀组 成新型精密树脂涂层系统,树脂涂层厚度达到0.02 mm。利用该系统制作了具有微流道的滴灌器件及其他微型零 件的原型。     

Determination of process parameters in stereolithography using neural network

For stereolithography process, accuracy of prototypes is related to laser power, scan speed, scan width, scan pattern, layer thickness, resin characteristics and etc. An accurate prototype is obtained by using appropriate process parameters. In order to determine these parameters, the stereolithography (SLA) machine using neural network was developed and efficiency of the developed SLA machine was compared with that of the traditional SLA. Optimum values for scan speed, hatching spacing and layer thickness improved the surface roughness and build time for the developed SLA.     

Optimum design of roll forming process of slide rail using design of experiments

In the design of the roll forming process, design errors can be determined in advance by using an FE simulation tool such as SHAPE-RF. In the case of a product such as a slide rail having a complicated shape and requiring high-precision forming, a standard is necessary for quantitatively evaluating the quality of the formed shape. In the analysis of the roll forming process of a slide rail, the pass having the largest deformation is designated as the target pass and the positions and shapes of the rolls are set as design variables. A minimum number of simulations was performed by using the table of orthogonal arrays. A cost function was obtained from the results by using the design of experiments such as the response surface method and it was minimized for satisfying the design constraints. By improving the design of the target pass, the shape of the final product approaches that intended by the designer.     

Microblasting characteristics of jewellery models built using stereolithography apparatus (SLA)

This paper describes an investigation of the effect of the microblasting process on the surface finish of jewellery models built using stereolithography apparatus (SLA). The layering process of SLA results in visible steps on the model surface. The investigation aims to determine the significant operating parameters of the microblaster deburring process that affect the surface roughness of the SLA jewellery model, to set a practicable range for these parameters for effective deburring and establish the optimum parameters for the best surface finish. A ring model based on the British Standards 28653: 1993 is designed using the Pro-Engineer software. The experimental strategy applies techniques including the full factorial and Yates' method together with the analysis of variance on the deburred samples. The surface roughness of the ring models before and after the deburring process are then measured with a Form Talysurf surface roughness measuring machine. The information obtained is used to identify the parameters for further study. Parameters identified are different nozzle types, blasting time and pressure variation. These parameters are tested for their optimum settings and the microblasting process is found to significantly improve the surface finish by approximately 30% on both the curvature and flat features of the ring model.     

Integrated simulation of the injection molding process with stereolithography molds

Functional parts are needed for design verification testing, field trials, customer evaluation, and production planning. By eliminating multiple steps, the creation of the injection mold directly by a rapid prototyping (RP) process holds the best promise of reducing the time and cost needed to mold low-volume quantities of parts. The potential of this integration of injection molding with RP has been demonstrated many times. What is missing is the fundamental understanding of how the modifications to the mold material and RP manufacturing process impact both the mold design and the injection molding process. In addition, numerical simulation techniques have now become helpful tools of mold designers and process engineers for traditional injection molding. But all current simulation packages for conventional injection molding are no longer applicable to this new type of injection molds, mainly because the property of the mold material changes greatly. In this paper, an integrated approach to accomplish a numerical simulation of injection molding into rapid-prototyped molds is established and a corresponding simulation system is developed. Comparisons with experimental results are employed for verification, which show that the present scheme is well suited to handle RP fabricated stereolithography (SL) molds.     

The design and manufacturing of porous scaffolds for tissue engineering using rapid prototyping

This research paper addresses the issue of developing an efficient methodology to design and manufacture a complex scaffold structure of desired porosity required for tissue engineering applications using a novel approach based on fused deposition modelling (FDM) rapid prototyping (RP) technology. The scaffold provides a temporary biomechanical structure for cell growth and proliferation to produce the required body parts. Conventional techniques of scaffold fabrication (such as fibre bonding, solvent casting and melt moulding) generate scaffolds with unpredictable pore sizes due to their limitations in flexibility and control of pore volume and distribution. Moreover, such scaffolds have poor mechanical strength and structural stability. The paper describes an FDM pre-processor that ensures the fabrication of scaffolds of desired porosity and inter-connectivity on the FDM system.     

熔融挤压快速成形特殊形状产品的工艺探讨

分析熔融挤压快速成形的工艺,针对三种特殊形状产品,从支撑、台阶效应、丝料特性等几个方面探讨了成形方向选择和壁厚控制对加工质量的影响,并成功加工出结构复杂产品、片状产品和薄壁半透明产品。     

Assessment of sculptured surface milling strategies using design of experiments

Product manufacturing on CNC milling machine tools involves a number of machining parameters and tool geometries. In the case of sculptured or free-form surfaces the number of these parameters can be significantly large and vary according to surface complexity. Minimising the number of parameters is carried out through statistical elimination. Design of experiments (DoE) along with the respective statistical analysis of variance (ANOVA) constitutes a low-cost useful tool in determining sub-optimum values for all parameters involved in each milling strategy as well as the most significant of those parameters. DoE was implemented for a particular sculptured surface assessing a variety of roughing and finishing strategies of a CAM simulation software.     

Optimal determination of production run and initial settings of process parameters for a deteriorating process

This paper presents a generalized model for the optimal determination of a production run and the initial settings of the process mean and process variance for a deteriorating production process. It is assumed that the process deteriorates due to tool wear-out. The probability that the process deterioration starts at a random point in time follows an exponential distribution. Quality loss from the target values is measured using Taguchi’s quadratic loss function. The time dependent maintenance cost and the salvage value of the equipment are included. The expressions for determining the optimal process mean and process variance are developed. Numerical examples are provided to demonstrate the application of the proposed model.     

Optimization of vacuum casting process parameters to enhance tensile strength of components using design of experiments approach

Vacuum casting is one of the widely used methods for small-volume production of plastic parts. The main challenge of this method is to choose the optimal w     

注射模工艺参数对塑件翘曲量的影响及优化

利用Moldflow分析软件,采用数值模拟的方法分析了料温、模具温度、注射时间、冷却时间和保压压力等工艺参数的变化对塑件产品翘曲的影响趋势及其原因。结果表明:对所选参数,保压压力对塑件翘曲的影响最为显著,且保压压力取注射压力的95%左右可使产品的翘曲量达到较小的程度;产品翘曲量随料温升高,注射时间减短而减小;冷却时间对翘曲量的影响甚微;模具温度对翘曲影响较为复杂。根据分析结果,优化了塑件的成型工艺参数,使得翘曲量进一步减小。     

Path planning effect for the accuracy of rapid prototyping system

Stereolithography (SL) is one of the rapid prototyping (RP) systems that use liquid photopolymer resin as the raw material for building prototypes. The photopolymer type of the RP system employs lasers to selectively expose the surface of the liquid resin. The absorbance of energy leads to photo-polymerization that transfers the liquid resin into solid. Subsequently, the phenomenon of volume shrinkage is unavoidable, and the curl distortion changes with the different laser scan paths, even affecting the geometric profile of the final-parts. The volume shrinkage and curl distortion are the major causes that lead to poor accuracy of the built prototype. In order to understand and improve the curl distortion and the geometric profile, so as to find a simple and suitable laser scan path. This paper first of all uses simulation and experiment to explore the deformation and shrinkage during the process of photo-polymerization while the liquid resin uses a laser beam to carry out single line scanning or single layer scanning in liquid free surface, and further understands the final change of geometric profile. Secondly, it investigates into the curl distortion and changes of geometric profile occurred in the three-dimensional part by different scan paths. Finally, a simple, proper, and effective laser scan path planning is suggested to decrease the curl distortion, and promote the dimension accuracy and the profile of the final-parts. Besides, this paper also mentions the feasibility of multi-optical processing.     

Process development for ball grid array assembly using a design of experiments approach

The focus of this work was to develop a robust assembly process for low and high input/output (I/O) ball grid arrays (BGAs). The test vehicles considered had a wide variety of components including full and perimeter array BGAs, and ultrafine pitch peripheral leaded devices. Experimental design techniques were applied in order to identify, screen, and control the parameters that affect the stencil printing process. The factors that affect the process were screened using Tagu-chi-based methodology. These significant factors and their interactions were then further analysed using full factorial designs. The volume and the quality of the solder paste deposits were considered as the response variables. Response surface plots were developed to provide process windows for paste deposition. Process capability studies were performed to evaluate the capability of the solder paste deposition process. Boards were assembled using optimal settings obtained from the experiments. No process-induced defects were found, and 100% yield was obtained.     

Application of rapid prototyping and rapid tooling for development of patient-specific craniofacial implant: an investigative study

In today’s competitive world, the life-style of the average human being has become very fast. This causes a huge number traffic accidents resulting in various types of injuries. In India, most of these accidents take place during bike riding and this causes different types of fracture of bones. One of these injuries is head injury. For the proper treatment of such patients, demands for patient-specific craniofacial bio-implants are increasing day by day. This kind of ‘tailored’ implant development through near net shape manufacturing is a highly challenging task since the developmental time and cost has to be as low as possible. At the Central Mechanical Engineering Research Institute (CMERI), one such process of implant development was explored taking one case of head injury. The implant was developed through the “3D CAD-rapid prototyping (RP)-rapid tooling (RT)-investment casting (IC)” route. For achieving the task, only the facilities available at CMERI were utilized.     

Use of design of experiments and Monte Carlo method for instruments optimal design

A common issue in the design of measurement instruments is the comparison between different solutions in terms of components of the measurement chain, data processing or even measurement principles; the predicted instrumental uncertainty is the driving parameter for such a comparison. While in many situations the linearization of the measuring model allows using the standard ISO GUM procedure, in complex cases it might be necessary to proceed with Monte Carlo simulations as per ISO GUM supplement 1. This paper describes a method that combines the factorial design of experiments (DOE) and the ISO GUM supplement 1 uncertainty evaluation method to guide the instrument designer in the instrument configuration optimization. The proposed approach allows estimating, in the design phase, the overall instrumental uncertainty for different configurations, the instrument sensitivity to the accuracy in the measurements of its inputs and the effects on systematic and random measurement errors deriving from the choice of all instrumental variables. The use of data populations selected with the DOE criteria allows recovering valuable parameters equivalent to the sensitivity factors of the GUM linearized approach. The data analysis allows separating the critical factors that must be accurately controlled from those only weakly affecting the measurement uncertainty. The method has been applied to a case study where the metrological performances of a system devoted to the measurement of the acoustic radiation emitted by a vibrating panel in a reverberant enclosure had to be assessed.     

Design of experiments approach to the study of tribological performance of Cu-concentrate-filled PPS composites

The tribological performance of copper-concentrate (CC) mineral deposit as the filler in polyphenylene sulfide (PPS) was studied as a function of the filler proportions and sliding test variables. CC is a complex mixture of CuS, Fe_xO_y, SiO₂, Al₂O₃, and other trace materials. The design of experiments based upon L₉ (3⁴) orthogonal arrays by Taguchi was used. Sliding tests were performed in the pin-on-disk configuration against a hardened tool steel (55-60 HRC) disk. The improvement in wear resistance of PPS was considerable with the use of fillers. The lowest steady state wear rate of 0.0030 mm³/km was obtained for PPS+20%CC+15%PTFE composition. It was two orders of magnitude lower than that of unfilled PPS. The variations in steady state coefficient of friction with the changes in filler proportions and sliding test variables were small. The transfer film was studied by atomic force microscopy (AFM) and scanning electron microscopy (SEM). X-ray photoelectron microscopy (XPS) was used to detect chemical reactive species developed during sliding, especially in the interface between transfer film and its counterface. Wear particles and the polymer worn surfaces were analyzed by energy dispersive spectroscopy (EDS) for elemental distribution.     

基于随形技术的快速制模工艺优化软件研究

针对在使用快速成形RP方法制造硅槔胶模中,硅橡胶成本昂贵,原型件制造速度慢的缺点,提出一种在使用RP设备加工RP原型件的同时,制造与之相配套的型腔与填充块方法,论述了相应工艺优化软件的关键技术。该方法大幅度降低了硅橡胶消耗,提高了原型件的加工速度。