"FAITH PRECISION"
PRECISION FA (ANE)
DESCRIPTION
The project consists of the development of a system and working method for the machining of metal parts manufactured using additive manufacturing technologies that enables machining on both sides of the parts. Said system and the application method must guarantee the positioning of parts between the additive manufacturing equipment and the machining equipment.
OBJECTIVES
1.1. Study of the state of the art of the positioning system between additive manufacturing and machining.
1.2. Study and identification of the metals of greatest interest at an industrial level by AM.
2.1. Study and definition of conditions to be met by the positioning system between SLM and machining.
2.2. Positioning system design between SLM and machining.
2.3. Manufacture of a functional prototype of a positioning system between SLM and machining.
3.1. Study and definition of conditions to be met by the positioning system between EBM and machining.
3.2. Positioning system design between EBM and machining.
3.3. Manufacture of a functional prototype of a positioning system between EBM and machining.
4.1. Study and definition of position and orientation conditions for parts to be manufactured with SLM and EBM and subsequently machined.
4.2. Study and definition of geometry oversizing criteria based on existing variables for subsequent machining.
4.3. Study and definition of the design of supports and reinforcement necessary to avoid deformations.
4.4. Definition of applicable machining strategies.
4.5. Manufacture of demonstrators in the developed systems.
5.1. Dimensional evaluation of the results obtained.
5.2. Study of the influence of heat treatments on the elimination of stresses and deformations.
5.3. Comparative study between machining parts in SLM and EBM by the classical method with respect to the proposed machining system.
6.1. Validation of the system and method developed through its application to two real demonstrators from different application sectors.
6.2. A plan for disseminating the results will be defined and implemented.
RESULTS OBTAINED
Año 2016:
2016 Year: Summary of the results obtained in the project
Deliverables:
Year 2016: An analysis of the state of the art of solutions applicable to the positioning of parts made with TFA has been carried out and it has been concluded that there is a great possibility of improvement with the proposed system, minimizing the sacrificial material.
The great diversity of industrial sectors that rely on the TFA has been demonstrated, as well as the most interesting materials for the industry such as steel, nickel-based alloys, titanium, cobalt-based alloys, aluminum, among others. Furthermore, it has been evaluated that in the solidification processes of metallic materials, localized stresses can be generated that can generate deformations that make the manufactured parts imprecise. This fact is worrying because it can limit the industrial use of the manufactured parts. Therefore, these generated deformations must be quantified and also attenuated/eliminated through the positioning and orientation of the pieces.
A specification has been defined for the precision system for machining parts obtained by SLM in a way that guarantees positioning, consumption of minimum sacrificial material, configurable, etc...
A positioning system has been designed between SLM and machining and between EBM and machining that meets all the premises established in the specifications.
The previously designed system has been manufactured and its correct operation has been verified.
A specification has been defined for the precision system for machining parts obtained by EBM in a way that guarantees positioning, consumption of minimum sacrificial material, configurable, etc...
The considerations to be taken into account and the process to follow have been established until reaching an optimal solution that allows the part to be positioned and oriented for manufacturing and subsequent machining.
The thickness to be added in the additive manufacturing process has been determined as the sum of the maximum values of the positioning error and the resulting surface roughness for the SLM and EBM technologies.
The bases have been specified for the design of supports with a clear thermal dissipation function and reinforcements for any geometry manufactured with SLM and EBM technologies, the latter based on topological design to minimize supports, guaranteeing rigidity for subsequent machining processes.
The processing sequence for the new proposed systems has been defined, reducing it from 10 steps for a standard system to 4 and 6 for the new systems proposed in SLM and EBM, respectively.
With precision systems, a piece with very complex geometry has been manufactured in SLM and EBM and it has been machined with a 5-axis machining center, demonstrating the viability of the process.
With the proposed systems, it is possible to improve the positioning error from 0.27mm in a standard system to 0.12mm for SLM and 0.1mm for EBM. With respect to the precision of the machining systems on one side, with respect to the precision achievable with the machining systems on two sides, it can be concluded that similar precisions are achieved with the developed systems.
Stress relief heat treatments modify the mechanical performance of materials but do not modify their dimensions, nor do they correct deformations or increase them.
A comparison has been made between the systems developed for EBM, SLM with respect to the classic method with respect to the following parameters: Positioning error, machining time and costs.
The developed systems have been validated by manufacturing and machining a demo part.
A roadmap has been developed for the expansion, promotion and dissemination of the results obtained.
GRANT
75.900,00 €
