additive manufacture of cores for aerospace: linking ...€¦ · additive manufacture of cores for...
TRANSCRIPT
![Page 1: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/1.jpg)
Additive manufacture of cores for aerospace: Linking quality
and controlDavid Pollard - [email protected] - 20th October 2016
SAMPE UK and Ireland Chapter 2016 Masterclass – Additive Manufacture
The Manufacturing Technology Centre, Ansty Park, Coventry
![Page 2: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/2.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
2
![Page 3: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/3.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
3
![Page 4: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/4.jpg)
Motivation
Source: http://www.3ders.org/articles/20160323-airbus-seeks-to-3d-print-half-of-its-future-airplane-fleet.html
4
![Page 5: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/5.jpg)
Motivation
• Aurora Flight Science and Stratasys collaboration
• Demonstrates feasibility of custom aircraft• Reduced cost
• Faster design time
Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciences
5
![Page 6: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/6.jpg)
Motivation
• Faster design iterations• 50% Design and Build time
reduction
• 80% AM components
• ULTEM FDM Plastic• Meets FAA Flame, Smoke, and
Toxicity (FST) requirements
Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciences
6
![Page 7: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/7.jpg)
Motivation
• Impossible Objects:• Composites Based Additive Manufacture (CBAM)
• Laminate-based method for long-fibre reinforcement printing
• Collaboration with Aurora Flight Sciences• Produced AM stabilisers capable of taking
landing load
Source: http://www.compositesworld.com/articles/3d-printed-composite-parts-provide-solution-for-uav
CompositesWorld: September 2016
7
![Page 8: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/8.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
8
![Page 9: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/9.jpg)
Introduction
• Processes• Vat Polymerisation
• Powder Bed Fusion
• Binder Jetting
• Material Jetting
• Sheet Lamination
• Material Extrusion
• Directed Energy Deposition
• ASTM F2792:• “process of joining materials to make
objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”
9
![Page 10: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/10.jpg)
Introduction
• Google Trends:• Search terms:
• 3D printing (Industry)
• Manufacturing (Industry)
• 3D printing was more commonly used than Additive Manufacturing
• Results are the percentage of peak searches
10
![Page 11: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/11.jpg)
Introduction
3D printing (Industry)
11
% o
f p
eak
sear
ches
![Page 12: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/12.jpg)
Introduction
3D printing (Industry)
Manufacturing (Industry)
12
% o
f p
eak
sear
ches
![Page 13: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/13.jpg)
Introduction
Bel
ief
Time
13
![Page 14: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/14.jpg)
Introduction
Bel
ief
Time
14
![Page 15: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/15.jpg)
Introduction
Bel
ief
Time
15
![Page 16: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/16.jpg)
Introduction
Bel
ief
Time
16
![Page 17: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/17.jpg)
Introduction
Source: European Commission Report:Identifying current and future application areas, existing industrial value chains and missing competences in the EU, in the area of additive manufacturing (3D-printing)
17
![Page 18: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/18.jpg)
Introduction
18
Ridged print failure - nozzle blockage
Sprue – insufficient retraction to stop flowSupport structures
Peeling from print bed
![Page 19: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/19.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
19
![Page 20: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/20.jpg)
Quality Definitions
• Quality:• Degree of excellence
• Conformance with requirements
• Totality of product features
• Fitness for use
• Freedom from defects, imperfections, or contamination
20
![Page 21: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/21.jpg)
Quality Definitions
• “Design process is a journey into the unknown, whereas the production process is a journey along a proven path with a predictable outcome” - David Hoyle, Quality Systems Handbook
• ISO 9001 requires: “establish procedures for identifying adequate statistical techniques required for verifying the acceptability product characteristics”
21
![Page 22: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/22.jpg)
Quality Definitions
22
Images from:http://aerospaceengineeringblog.com/sandwich-panel/http://communicats.blogspot.co.uk/p/technical-art.html
Face sheets
Adhesive material
Core splicing
Core type 1
Core type 2 Core type 2
Insert
![Page 23: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/23.jpg)
Quality Definitions
AM Aerospace Core
Manufacturing Design
Machine location?
Which process?
Manufacturing workflow?
Component optimisation?
Fulfilling requirements?
Design workflow?
23
Customer Input
![Page 24: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/24.jpg)
Quality Definitions
AM Aerospace Core
Manufacturing Design
Machine location?
Which process?
When in the process?
Component optimisation?
Fulfilling requirements?
Design workflow?
Quality Assurance
24
Customer Input
![Page 25: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/25.jpg)
Quality Definitions
AM Aerospace Core
Manufacturing Design
Quality Control
Machine location?
Which process?
When in the process?
Component optimisation?
Fulfilling requirements?
Design workflow?
Quality Assurance
25
Customer Input
![Page 26: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/26.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
26
![Page 27: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/27.jpg)
Assuring Quality
• FDA – Technical Considerations for Additive Manufactured Devices• Draft guidance for qualifying medical devices
• Highlights need for documentation
• Separation of Geometry/Build certification
• Difficulties in inspection of internal defects and complex geometries
Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.Images: http://www.bbc.co.uk/news/technology-34044453http://www.wakehealth.edu/WFIRM/
27
![Page 28: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/28.jpg)
Assuring Quality
• Geometric Dimensions and Tolerancing (GD&T)• Common accuracy control
• Suited for 2D Shapes
Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.
28
![Page 29: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/29.jpg)
Assuring Quality
• Geometric Dimensions and Tolerancing (GD&T)
• Product and Manufacturing Information (PMI)• Complex curvatures
• Strong Process/Product interaction
• Not meant for human interpretation
Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.
29
![Page 30: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/30.jpg)
Assuring Quality
• Process inputs
• Thermal:• Contraction of layers during cooling
• Inter-layer bonding effects
• Mechanically induced:• Machine vibration
• Variable flow rates
Image: https://www.simplify3d.com/support/print-quality-troubleshooting/
30
![Page 31: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/31.jpg)
Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
31
![Page 32: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/32.jpg)
Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Layer thicknessSpeedFlow rateNozzle temperatureNozzle diameterPart orientationRaster angleInfill type/density
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
32
![Page 33: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/33.jpg)
Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Filament shape + sizeRheologyElastic modulus
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
33
![Page 34: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/34.jpg)
Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Chamber temperatureMechanical responseAir properties
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
34
![Page 35: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/35.jpg)
Assuring Quality
• Thermal distortion• Can cause separation from build surface
• Affects final accuracy
• Can be predicted and reduced based on model
• Thermal bonding• Layers bond above Tg
• Modelling of heat flow during print
Source: Huang, Q., Zhang, J., Sabbaghi, A. and Dasgupta, T., 2015. Optimal offline compensation of shape shrinkage for three-dimensional printing processes. IIE Transactions, 47(5), pp.431-441.
35
![Page 36: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/36.jpg)
Assuring Quality
• Thermal distortion modelling• Traditionally constrained my
CAD/Simulation tools
• Functional Generative Design:• Developed by Dassault Systèmes
• CATIA geometry
• Abaqus FEA
• Tosca topology optimisation
Image: http://perspectives.3ds.com/tag/functional-generative-design/Source: CompositesWorld September 2016, p13
36
![Page 37: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/37.jpg)
Assuring Quality
• Cores produced through FDM tested in compression
• Similar ultimate stress for wall thickness variation
• Different failure characteristics• Especially compared to Nomex
37
Source: Pollard, D., Ward, C., Herrmann, G., Etches, J., 2016. Manufacture of Honeycomb Cores through Fused Deposition Modelling. Proceedings of the 17th European Conference on Composite Materials
![Page 38: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/38.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
38
![Page 39: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/39.jpg)
Progress in Control
• Flow control• Iterative Learning Control
• Different flow states discretised
• Road thickness variations used to modify input signal for next iteration
• 80% reduction of RMS error
Source: Hoelzle, D.J., Alleyne, A.G. and Johnson, A.J.W., 2009, June. Iterative Learning Control using a basis signal library. In 2009 American Control Conference (pp. 925-930). IEEE.
39
![Page 40: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/40.jpg)
Progress in Control
• Machine control• Majority of low-cost printers use open-
loop stepper motors
• With axis encoders and PI control, 75% reduction in tracking error for jagged contours
Source: Weiss, B.M., 2014. Closed-Loop Control of a 3D Printer Gantry (Doctoral dissertation, University of Washington).
NB: Errors radially amplified by 20x
40
![Page 41: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/41.jpg)
Progress in Control
• MarkForged X• Prints with carbon
reinforcement
• 50 µm resolution
• Laser scanner for part accuracy checks
Source: https://markforged.com/introducing-the-mark-x/
41
![Page 42: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/42.jpg)
Progress in Control
Additive/Subtractive manufacture
Source: Keating, S. and Oxman, N., 2013. Compound fabrication: A multi-functional robotic platform for digital design and fabrication. Robotics and Computer-Integrated Manufacturing, 29(6), pp.439-448.
42
![Page 43: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/43.jpg)
Progress in Control
Surface scanning and printing
Source: Song, X., Pan, Y. and Chen, Y., 2015. Development of a low-cost parallel kinematic machine for multidirectional additive manufacturing. Journal of Manufacturing Science and Engineering, 137(2), p.021005.:
43
![Page 44: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/44.jpg)
Progress in Control
Source: Song, X., Pan, Y. and Chen, Y., 2015. Development of a low-cost parallel kinematic machine for multidirectional additive manufacturing. Journal of Manufacturing Science and Engineering, 137(2), p.021005.
Full video available from: https://www.youtube.com/watch?v=qGyiXFGvkqE
44
![Page 45: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/45.jpg)
Progress in Control
• Superimposition of object over surface for 3D printing
• Identified key issues for multi-dimensional printing• Tight tolerance for nozzle positioning
• Requires stiff mechanical system
45
Source: Bausch, N., Dawkins, D., Frei, R., Klein, S., 2016.3D Printing onto Unknown Uneven Surfaces. Proceedings of the 7th
IFAC Symposium on Mechatronic Systems
![Page 46: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/46.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
46
![Page 47: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/47.jpg)
AM Cores in Aerospace
• Optimisation of honeycomb cores for required loads• Reinforcement for higher stress concentrations
• Variations in cell density or shape around holes
• Curved panels production with no added complexity
Source: Riss, F., Schilp, J. and Reinhart, G., 2014. Load-dependent optimization of honeycombs for sandwich components–new possibilities by using additive layer manufacturing. Physics Procedia, 56, pp.327-335.
47
![Page 48: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/48.jpg)
AM Cores in Aerospace
• Boeing Patent US 2004/0048027• “Honeycomb Cores for Aerospace Applications”
• Discuss key advantages:• Reduces manufacturing cost for complex Radar
Cross Section
• Internal features and geometry
• Multiple gradients of material for testing reduction
48
Source: Hayes, M., DeGrange, J., Rice, C. and Polus, J., Hayes Michael W., DegrangeJeffrey E., Rice Christian V. and Polus Jeffrey E., 2002. Honeycomb cores for aerospace applications. U.S. Patent Application 10/236,361.
![Page 49: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/49.jpg)
AM Cores in Aerospace
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
49
![Page 50: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/50.jpg)
AM Cores in Aerospace
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
50
![Page 51: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/51.jpg)
AM Cores in Aerospace
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
51
![Page 52: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/52.jpg)
AM Cores in Aerospace
52
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
![Page 53: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/53.jpg)
AM Cores in Aerospace
Source: Pollard, D., 2014, Automated sandwich panel production utilisingadditive manufacture and silicone pick and place technology, Masters Thesis, University of Bristol
53
![Page 54: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/54.jpg)
AM Cores in Aerospace
Source: Pollard, D., 2014, Automated sandwich panel production utilisingadditive manufacture and silicone pick and place technology, Masters Thesis, University of Bristol
54
![Page 55: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/55.jpg)
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
55
![Page 56: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/56.jpg)
Further work
• Efficient structure
• Manufacturability
• Increased functionality
Design optimisation
• Failure monitoring
• Reduction of manual input
• In-process quality control
Reliability in production
• Non Destructive Testing
• Quality Assurance/Control
• Advances in qualification processesPart verification
56
![Page 57: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/57.jpg)
Selection of further reading• Review papers:
• Huang, Y., Leu, M.C., Mazumder, J. and Donmez, A., 2015. Additive manufacturing: current state, future potential, gaps and needs, and recommendations. Journal of Manufacturing Science and Engineering, 137(1), p.014001.
• Huang, T., Wang, S. and He, K., 2015, October. Quality control for fused deposition modeling based additive manufacturing: Current research and future trends. In Reliability Systems Engineering (ICRSE), 2015 First International Conference on (pp. 1-6). IEEE.
• Guessasma, S., Zhang, W., Zhu, J., Belhabib, S. and Nouri, H., 2015. Challenges of additive manufacturing technologies from an optimisation perspective. International Journal for Simulation and Multidisciplinary Design Optimization, 6, p.A9.
• Modelling and Process Control:• Sun, Q., Rizvi, G.M., Bellehumeur, C.T. and Gu, P., 2008. Effect of processing conditions on the bonding quality of FDM polymer
filaments. Rapid Prototyping Journal, 14(2), pp.72-80
• Huang, Q., Nouri, H., Xu, K., Chen, Y., Sosina, S. and Dasgupta, T., 2014. Statistical predictive modeling and compensation of geometric deviations of three-dimensional printed products.Journal of Manufacturing Science and Engineering, 136(6), p.061008.
• Yoon, J., He, D. and Van Hecke, B., 2014, September. A PHM approach to additive manufacturing equipment health monitoring, fault diagnosis, and quality control. In Proceedings of the Prognostics and Health Management Society Conference, Fort Worth, TX, USA (Vol. 29, pp. 1-9).
57
![Page 58: Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for aerospace: Linking quality and control David Pollard - dp0084@bristol.ac.uk - 20th](https://reader034.vdocuments.net/reader034/viewer/2022042917/5f58dfe56d6c6305f6184096/html5/thumbnails/58.jpg)
Acknowledgements
• Supervisors: Dr Carwyn Ward, Dr Guido Herrmann, Dr Julie Etches
• This work was supported by the EPSRC Centre for Doctoral Training in Future Autonomous Robotic Systems (FARSCOPE) at the Bristol Robotics Laboratory, (grant: EP/L015293/1).
58