Dimensional Accuracy and Surface Finish in Additive Manufacturing

244 Pages·2014·44.33 MB·English

Proceedings
ASPE 2014 Spring Topical Meeting
Dimensional Accuracy and Surface Finish
in Additive Manufacturing
April 13-16, 2014
P.O. Box 10826, Raleigh, NC 27605-0826
[phone] | Fax [phone]

Preface
This book comprises the proceedings of the ASPE 2014 Spring Topical Meeting entitled
Dimensional Accuracy and Surface Finish in Additive Manufacturing. The contributions
reflect the authors’ opinions and are published as presented to ASPE without change. Their
inclusion in this publication does not necessarily constitute endorsement by the ASPE or its
editorial staff.
Individual readers of this book and nonprofit libraries acting for them are permitted to make fair
use of the material contained in this book to be used in teaching or research; provided they
copy said paper in total, as written by the author. Permission is granted to quote excerpts
from the scientific or technical works in this book with proper acknowledgment of the source
to include: The author’s name, the book name, and the ASPE tag line. Reproduction of
figures and tables is likewise permitted from the contents of this book, provided that the
same acknowledgment of the same source and content is permitted.
Any other type reproduction, systematic copying or multiple reproduction of any material in
this book is expressly prohibited except with the written permission of the ASPE editorial
staff, addressed to the Society’s headquarters.
ISBN 978-1-887706-64-3
2014
American Society for Precision Engineering
301 Glenwood Avenue, Suite 205
Raleigh, NC 27603
Printed in the United States of America
ii
Proceedings of
Dimensional Accuracy and Surface Finish
in
Additive Manufacturing
ASPE Spring Topical Meeting
April 13-16, 2014
University of California - Berkeley
Berkeley, California, USA
The American Society for Precision Engineering (ASPE) is a multidisciplinary professional
and technical society concerned with research and development, design, manufacture and
measurement of high accuracy components and systems. ASPE activities encompass relevant
aspects of mechanical, electronic, optical and production engineering, physics, chemistry, and
computer and materials science. Membership is open to anyone interested in any aspect of
precision engineering.
Founded in 1986, ASPE provides a new focus for a diverse but important community. Other
professional organizations have covered aspects of precision engineering, always as a sideline
to their principal goals. ASPE is based on the core of generic concepts necessary to achieve
precision in any application; independent of discipline, ASPE intends to be the focus for
precision technology, and to represent all facets from research to application.
ASPE – The American Society for Precision Engineering
301 Glenwood Avenue, Suite 205, Raleigh, NC 27603
P.O. Box 10826, Raleigh, NC 27605
Telephone: [phone] Fax [phone]
Web site: aspe.net
i
Table of Contents
Preface ...................................................................... ii
Contents .....................................................................iii
Schedule .....................................................................iv
Foreword .....................................................................v
Sustaining Corporate Sponsors ...................................................vi
Corporate Sponsors ........................................................... vii
Technical Paper Index .......................................................viii - xiii
Technical Papers ...........................................................3 - 224
Author Index ............................................................225 - 226
iii
Meeting S chedule

Mon., April 14 Tues., April 15 Wed., April 16
Sun., April 13 UC-Berkeley UC-Berkeley UC-Berkeley
Hotel Shattuck Bechtel Building Bechtel Building Bechtel Building
Sibley Auditorium Sibley Auditorium Sibley Auditorium

7:00 Registration and

Continental Breakfast
7:30 7:30 7:30
Registration and Registration and Registration and
8:00 Continental Breakfast Continental Breakfast Continental Breakfast
TUTORIAL I
Crystal Ballroom II 8:15 8:15 8:15
CrTysUtaTlO BR aIlAlroLo ImI I RWSPEELEMSELASNCRIAOOKRMNSYE I& OPEONDPSIENTESGISMI GSRIZINEOA MNATAN IIOIRDI NK S & OPECMNSHEEIANTSLGRSLO& IERO LNENOGM GVEAYIS R KS

10:00 Coffee Break 10:00 Coffee Break 10:00 Coffee Break 10:00 Coffee Break
10:30 10:30 10:30 10:30
TUTORIAL I & II
SESSION II SESSION IV
CONTINUED SESSION VII
PLENARY MICMROODSETLRIUNCGT &U RE VALIDATION OF
11:30 AM PROCESSES
Boxed Lunch AND TOOLS
12:00 12:00
12:30 12:30
CTOUNTOTIRNIUAELD I On-YLuonucr-hO wn On-YLuonucr-hO wn Lun ch
On-Your-Own
1:30 1:30 1:30
Coffee Break

1:45 COMMERCIAL SESSION V 2:00
SESSION NEW
TUTORIAL I DEVELOPMENTS IN
CONTINUED AM TOOLS SESSION VIII
AND HYBRID ACHIEVING
PROCESSES TIGHT
3:00 TOLERANCES
Coffee Break
3:15
Coffee Break
3:30 3:30 3:30
Coffee Break
COMMERCIAL
AND 3:45 3:45 Coffee Break
TUTORIAL I TECHNICAL COMMERCIAL
CONTINUED POSTERS AND 4:00 SESSION IX
Garbarini Lounge TECHNICAL METROLOGY
POSTERS
OF
5:00 5:00 BHUOST ETLO/ 5:15 Garbarini Lounge 5:30 ENDS CUORNFF AECREESN CE
PYRAMID ALEHOUSE*

6:00 6:00

6:30
WELCOME
RECEPTION

CRYSTAL
BALLROOM PYRAMID ALEHOUSE After-Meeting
8:00 DINNER Gathering
The Faculty Club

9:00
iv
*Bus will make brief stop at near-by hotels to drop-ff personal belongings before going dinner.
iv
Foreword
This meeting of the American Society for Precision Engineering on Dimensional Accuracy and
Surface Finish in Additive Manufacturing will focus on 1) Dimensional Accuracy and Surface
Finish from Additive Manufacturing (AM): what dimensional control is needed for AM for precision
applications; State-of-the-Art – what is achievable today and what developments are underway;
issues and timeline for meeting precision tolerances (Gap analysis). 2) Design for manufacturing:
design rules for additive manufacturing and impact of dimensional errors on structures designed
using optimization methodologies. 3) Standards: certifying AM equipment capabilities and artifacts
for assessing machine performance – Round-robin testing. 4) Using AM-Fabricated components in
precision assemblies: component-to-component relationships, stack-up tolerances, friction, robotic
grip-ability. 5) Combining AM with secondary finishing operations 6) Metrology: external surfaces
and internal features; in-situ instrumentation; materials validation and 7) Mechatronics and controls
for achieving dimensional tolerances.
We encourage presentations of a tutorial nature which elaborate principles essential to achieving
high performance. We aim to bring together specialists and practitioners from industry, government,
and academia for the exchange of ideas and to identify topics for further research. The conference
schedule will include significant unstructured time to allow for technical and social interactions.
2014 Spring Topical Meeting Program Committee
Meeting Chairman:
John S. Taylor
Lawrence Livermore National Laboratory
Organizing Committee:
Vivek G. Badami, Zygo Corporation
Ryan R. Dehoff, Oak Ridge National Laboratory
David A. Dornfeld, University of California at Berkeley
Thomas A. Dow, North Carolina State University
Andreas Fischer-Ludwig, Siemens Energy, AG
Pete J. Fitsos, Lawrence Livermore National Laboratory
Allister James, Siemens Energy, Inc.
Bradley H. Jared, Sandia National Laboratories
Sanjay Joshi, The Pennsylvania State University
Fred van Keulen, Technical University of Delft
Wayne King, Lawrence Livermore National Laboratory
Howard A. Kuhn, University of Pittsburgh
Thomas R. Kurfess, Georgia Institute of Technology
Richard K. Leach, National Physical Laboratory
Stephen J. Ludwick, Aerotech, Inc.
Shawn P. Moylan, National Institute of Standards and Technology
Gregory T. Pawlikowski, TE Connectivity
Senajith (Seno) Rekawa, Lawrence Berkeley National Laboratory
Todd Rockstroh, GE Aviation
Alexander H. Slocum, Massachusetts Institute of Technology
Christopher Spadaccini, Lawrence Livermore National Laboratory
Eckart Uhlmann, Fraunhofer Institute for Production Systems and Design Technology, Berlin
Ryan Wicker, W.M. Keck Center for 3D Innovation, UTEP
v
ASPE 2014 Sustaining Corporate Sponsors
Chardon Tool
115 Parker Court
3M Company Chardon, OH 44024 Moore Nanotechnology Systems LLC
St. Paul, MN 55144
Phone: [phone] Old Homestead Highway
Phone: [phone]
Fax: [phone] Swanzey, NH 03446
www.mmm.com
www.ChardonTool.com Phone: [phone]
www.nanotechsys.com
Cranfield Precision
Division of Cinetic Landis Ltd.
Woburn House
Aerotech, Inc.
3 Adams Close
101 Zeta Drive nPoint, Inc.
Kempston, Bedford, MK42 7 JE
Pittsburgh, PA 15238-2897 3030 Laura Lane, Suite 100
United Kingdom
Phone: [phone] Middleton, WI 53562 USA
Fax: [phone] Phone: [phone]
Phone: [phone]
www.aerotech.com www.cranfieldprecision.com
www.npoint.com
Agilent Technologies, Inc.
Lion Precision Professional Instruments Company
5301 Stevens Creek Boulevard
563 Shoreview Park Road 7800 Powell Road
P.O. Box 58059
St. Paul, MN 55126-7014 Hopkins, MN 55343
Santa Clara, CA 95052-8059 USA
Phone: [phone] Phone: [phone]
Phone: [phone]
Fax: [phone] Fax: [phone]
www.home.agilent.com
www.lionprecision.com www.airbearings.com
AMeTek-Precitech, Inc.
44 Blackbrook Road Specialty Components, Inc.
Keene, NH 03431 Makino 14 Village Lane
7680 Innovation Way
Phone: [phone] Wallingford, CT 06492
Mason, OH 45040
Fax: [phone] Phone: [phone]
Phone: [phone]
www.precitech.com Fax: [phone]
Fax: [phone]
www.specialtycomponents.com
www.makino.com
Mitutoyo America Corporation Trust Automation, Inc.
945 Corporate Boulevard 143 Suburban Road
Carl Zeiss Industrial Metrology LLC
Aurora, IL 60504-9102 San Luis Obispo, CA 93401
6250 Sycamore Lane North
Phone: [phone] Phone: [phone]
Maple Grove, MN, 55369
Phone: [phone] Fax: [phone] Fax: [phone]
www.zeiss.com/metrology www.mitutoyo.com www.trustautomation.com
vi
ASPE 2014 Corporate Sponsors
ADCOLe Corporation Delta Tau Data Systems
669 Forest Street 21314 Lassen Street
Marlborough, MA 01752 Chatsworth, CA 91311 USA
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
www.adcole.com www.deltatau.com
Alicona k & Y Diamond
1261 Humbracht Circle 2645 Diab St. Laurent
Suite G Quebec H4S 1E7
Bartlett, IL 60103 USA CANADA
Phone: [phone] Phone: [phone]
www.alicona.com Fax: [phone]
www.kydiamond.ca
Contour Fine Tooling, Inc.
143 Jaffrey Road nanoPrecision Products, Inc.
Marlborough, NH 03455 411-B Coral Circle
Phone: [phone] El Segundo, CA 90245
Fax: [phone] Phone: [phone]
www.contour-diamonds.com www.nanoprecisionproducts.com
Center for Precision Metrology Zygo Corporation
University of North Carolina at Charlotte Laurel Brook Road
9201 University Blvd. Middlefield, CT 06455-0448
Charlotte, NC 28223 Phone: [phone]
Phone: [phone] Fax: [phone]
cpm.uncc.edu/ Toll-free: (800) ZYGO-NOW
www.zygo.com
Corning Inc.
Corning, NY 14831
Phone: [phone]
www.corning.com
vii
Technical Sessions
Session I
Plenary
Monday, April 14, 2014, 8:15 AM - 10:00 AM
Session Chairs: John S. Taylor, Lawrence Livermore National Laboratory and
Eckart Uhlmann, Fraunhofer Institute for Production Systems and Design, Berlin
1. Welcome and Opening Remarks
Taylor, J. S. (Lawrence Livermore National Laboratory)
2. Ge Aviation Perspective on Precision Capabilities of Additive Manufacturing
Rengers, S. (GE Aviation) .............................................................3
3. Metrology Needs for Additive Manufacturing
Kurfess, T. R. (Georgia Institute of Technology); Taylor, J. S. (Lawrence
Livermore National Laboratory) ........................................................4
4. Modeling and Simulation of Additive Manufacturing Processes
King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.;
Khairallah, S. A. (Lawrence Livermore National Laboratory) ..................................7
Session II
Plenary
Monday, April 14, 2014, 10:30 AM - 12:00 PM
Session Chairs: David A. Dornfeld, University of California - Berkeley and
Vivek G. Badami, Zygo Corporation
1. Topology Optimization and Additive Manufacturing, Natural Counterparts
for Precision Systems - State-of-the-Art and Challenges
van Keulen, F.; Langelaar, M. (Delft University of Technology);
van Baars, G. (TNO Technical Sciences) .................................................9
2. An engineered Approach for Combined Additive and Subtractive Manufacturing*
Lell, F. (DMG-Mori Seiki, Sauer GmbH)
3. Metals-Based Additive Manufacturing: Metrology Needs and Standardization efforts
Slotwinski, J. A.; Moylan, S. P. (National Institute of Standards and Technology) ................11
Commercial Session
Monday, April 14, 2014, 1:30 PM - 3:00 PM
Session Chairs: Pete J. Fitsos, Lawrence Livermore National Laboratory and
Alexander H. Slocum, Massachusetts Institute of Technology
*No abstract provided at this time
viii