Digital Manufacturing: The Industrialization of "Art to Part" 3D Additive Printing

485 Pages·2022·9.661 MB·English

by  Chandrakant D. Patel, Chun-Hsien Chen

Digital Manufacturing
The Industrialization of “Art to Part” 3D Additive Printing
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Digital Manufacturing
The Industrialization of “Art to Part” 3D
Additive Printing
Edited by
Chandrakant D. Patel
HP Chief Engineer and Senior Fellow,HP Inc., PaloAlto, CA,
UnitedStates
Chun-Hsien Chen
HP-NTU Digital Manufacturing Corporate Lab,
Schoolof Mechanicaland AerospaceEngineering,
Nanyang Technological University, Singapore
Elsevier
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Contents
Listofcontributors xiii
Preface xv
Acknowledgments xvii
1. A historical perspective on industrial production
and outlook 1
ChorHiongTee
Abbreviations 1
1.1 Introduction 2
1.2 Preindustrialization 3
1.2.1 Craftproduction 3
1.2.2 Agriculturalrevolution 3
1.3 FirstIndustrialRevolution 4
1.3.1 Mechanization 4
1.3.2 Laissez-fairecapitalism 4
1.3.3 Socialandenvironmentalimpact 5
1.4 SecondIndustrialRevolution 6
1.4.1 Divisionoflabor 6
1.4.2 Massproduction 7
1.4.3 Batchproduction 8
1.5 ThirdIndustrialRevolution 9
1.5.1 Automation 11
1.5.2 Numericalcontrol 12
1.5.3 Industrialrobots 14
1.5.4 Earlycomputers 15
1.5.5 Grouptechnology 18
1.5.6 Moderncomputers 23
1.5.7 Computersystemarchitecture 23
1.5.8 Computer-aidedapplications 26
1.5.9 Computer-integratedmanufacturing 33
1.5.10 Productdevelopmentprocess 36
1.5.11 Additivemanufacturing 41
1.5.12 Sustainabilityinmanufacturing 42
1.6 ForthIndustrialRevolution 46
1.6.1 Industrie4.0 47
1.6.2 Cyber-physicalsystem 49
1.6.3 Factoryofthefuture 50
v
vi Contents
1.7 Summary 52
References 53
2. Digital product design and engineering analysis
techniques 57
TianyuZhou,WeidanXiong,YukiObata,CarlosLangeand
YongshengMa
Abbreviations 57
2.1 Introduction 58
2.2 Productdesignprocess 58
2.3 3Ddigitalformcreation 59
2.3.1 3Ddigitalforms 61
2.3.2 Formmodeling 64
2.3.3 Casestudy 66
2.4 Intent-basedsystemicdesign 69
2.4.1 Functionalfeatureapproach 70
2.4.2 Feature-basedcomputer-aideddesignmodeling 73
2.4.3 Twotypicaldecision-makingtypes:retrievaland
inspirational 80
2.5 Engineeringanalysis 82
2.5.1 Computationalfluiddynamicssimulation 83
2.5.2 Casestudy 86
2.6 Currentchallengesandfuturework 89
2.6.1 Currentchallenges 91
2.6.2 Expectedfuturework 92
2.7 Summary 94
References 94
3. Design methodologies for conventional and additive
manufacturing 97
XueTingSong,Jo-YuKuoandChun-HsienChen
Listofabbreviations 97
3.1 Introduction 97
3.1.1 DesignforAssembly 98
3.1.2 DesignforManufacturing 98
3.2 Designmethodologiesforconventionalmanufacturing 100
3.2.1 DesignforManufacturingandAssemblyguidelines 100
3.2.2 DesignforManufacturingandAssemblyprocedures 101
3.2.3 ApplicationsofDesignforManufacturingandAssembly 108
3.2.4 LimitationsofDesignforManufacturingandAssembly 110
3.3 Aparadigmshift 112
3.3.1 DesignforX 112
3.3.2 DesignforAdditiveManufacturing 113
3.3.3 Trendofhybridmanufacturingproduction 116
Contents vii
3.4 Designmethodologiesforadditivemanufacturing 117
3.4.1 NotableDesignforAdditiveManufacturingresearch
works 117
3.4.2 DesignstagesofageneralDesignforAdditive
Manufacturingframework 119
3.4.3 ChallengesofDesignforAdditiveManufacturing 136
3.5 Summary 140
References 140
4. Additive manufacturing for digital transformation 145
YuYingClarrisaChoong
Listofabbreviation 145
4.1 Introductiontoadditivemanufacturing 146
4.1.1 Definitionsandterminologies 146
4.1.2 Overviewoftheadditivemanufacturingmarket 147
4.1.3 Industrydriversforadditivemanufacturingadoption 150
4.2 Additivemanufacturingprocesschain 152
4.2.1 Levelofadditivemanufacturingimplementation 152
4.2.2 Design,optimization,andsimulation 154
4.2.3 Materialselection 155
4.2.4 Manufacturing 155
4.2.5 Postprocessing 155
4.2.6 Processmonitoringandvalidation 157
4.3 Additivemanufacturingtechnologiesandprocesses 158
4.3.1 Vatphotopolymerization 158
4.3.2 Materialextrusion 164
4.3.3 Materialjetting 165
4.3.4 Sheetlamination 168
4.3.5 Powderbedfusion 170
4.3.6 Binderjetting 173
4.3.7 Directedenergydeposition 174
4.4 Casestudiesofadditivemanufacturingduringthe
COVID-19pandemic 176
4.4.1 Providingrapidemergencyresponses 177
4.4.2 Masscustomizations 178
4.4.3 Agileoperationsandacceleratedproductions 178
4.4.4 Preservingsustainabilityandcontinuity 178
4.5 Summary 180
References 180
5. Simulation and optimization for additive
manufacturing 183
HowWeiBenjaminTeo,KimQuyLe,KokHongGregoryChua
andHejunDu
Abbreviations 183
Symbols 183
viii Contents
5.1 Introduction 185
5.1.1 Macroscalemodeling 186
5.1.2 Mesoscalemodeling 187
5.1.3 Microscalemodeling 187
5.1.4 Parametersoptimization 188
5.1.5 Objectives 188
5.2 Areviewofmodelsemployinginadditivemanufacturing
simulations 188
5.2.1 Powderinteraction 189
5.2.2 Heattransferandmeltpooldynamics 191
5.2.3 Lightsourcesimulation 195
5.2.4 Crystallization/microstructuresimulation 198
5.2.5 Summary 206
5.3 Topologyoptimization 207
5.3.1 Structuraloptimization 208
5.3.2 Typesoftopologyoptimizationmethodologies 210
5.3.3 Topologyoptimizationworkflowforadditive
manufacturing 211
5.3.4 Availablecommercialsoftwarefortopology
optimization 214
5.4 Summary 216
References 216
6. Polymer materials for additive manufacturing 221
JiaAn
Listofabbreviation 221
6.1 Introduction 221
6.1.1 Molecularmaterial(cid:1)relatedclassifications 222
6.1.2 Molecularstructure(cid:1)relatedclassifications 223
6.1.3 Polymerclassificationforadditivemanufacturing 223
6.2 Thermosets 224
6.2.1 Curing 224
6.2.2 Curingcharacteristics 225
6.2.3 Dynamiccovalentbonds 229
6.3 Thermoplastics 229
6.3.1 Polymermelt 229
6.3.2 Rheologicalproperties 231
6.3.3 Thermalproperties 232
6.4 Printabilityin3Dprinting 234
6.4.1 Layering 234
6.4.2 Energyandmaterialbonding 236
6.5 Characteristicsof3Dprintedparts 240
6.5.1 Porosity 241
6.5.2 Anisotropy 241
6.5.3 Heterogeneity 242
Contents ix
6.6 Summary 243
6.7 Furtherrecommendation 243
References 243
7. Metal additive manufacturing 247
ChaoCaiandKunZhou
Abbreviations 247
7.1 Introduction 248
7.2 Classificationofmetaladditivemanufacturingtechnology 249
7.2.1 Powderbedfusion 249
7.2.2 Directenergydeposition 252
7.2.3 Binderjetting 254
7.2.4 Sheetlamination 255
7.3 Preparationandcharacterizationtechniquesformetal
additivemanufacturingfeedstock 258
7.3.1 Powderpreparationtechniques 258
7.3.2 Powdercharacterizationtechniques 260
7.4 Mechanicalpropertiesstandardtestingformetallic
additivemanufacturingcomponents 263
7.4.1 Tension 263
7.4.2 Compression 263
7.4.3 Hardness 266
7.4.4 Fatigueperformance 268
7.5 Defectsinmetallicadditivemanufacturingcomponents 268
7.5.1 Defectcategories 270
7.5.2 Defectsdetectiontechniques 277
7.6 Postprocessing 281
7.6.1 Removalofadhesivepowders,supportstructures,and
substrateplates 281
7.6.2 Heattreatment 283
7.6.3 Surfacefinishing 283
7.7 Applications 284
7.7.1 Aerospace 285
7.7.2 Automotiveindustry 288
7.7.3 Healthcare 290
7.8 Conclusionandperspectives 293
References 294
8. The emerging frontiers in materials for functional
three-dimensional printing 299
JiaMinLee,SweeLeongSing,GuoDongGoh,
GuoLiangGoh,WeiLongNgandWaiYeeYeong
Listofabbreviations 299
8.1 Introduction 300
8.2 Compositesmaterialsforaerospaceindustry 302