v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables ix
List of Figures x
List of Abbreviations, Symbols and Nomenclatures xiii
CHAPTER 1: INTRODUCTION 1
1.1 Introduction
1 1.2
Problem statement 3
1.3 Objective
3 1.4
Scope of project 4
1.5 Activity planning
4
CHAPTER 2: LITERATURE REVIEWS 7
2.1 Additive Manufacturing
7 2.2 Step in AM.
8 2.2.1 Step 1: Conceptualization and CAD
8 2.2.2 Step 2: STL File Conversion
10 2.2.3 Step 3: Transfer to AM Machine and STL File Manipulation 10
2.2.4 Step 4: Machine Setup 11
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2.2.5 Step 5: Build 11
2.2.6 Step 6: Removal and Cleanup 12
2.2.7 Step 7: Post-process 12
2.2.8 Step 8: Application 13
2.3 Stereolithography SLA
14 2.4
Selective Laser Sintering SLS 15
2.5 Fused Deposition Modelling
16 2.5.1 Process of FDM
16 2.6
Ultrasonic transducer 18
2.6.1 Ultrasonic transducer in machining 20
2.7 ANSYS
23 2.8
Magnesium alloy 24
CHAPTER 3: METHODOLOGY 26
3.1 Introduction
26 3.2
General Project Planning 27
3.2.1 Phase 1 28
3.2.1.1 Identify problem statement. 28
3.2.1.2 Literature review 28
3.2.1.3 Methodologies 28
3.2.2 Phase 2 28
3.2.2.1 Develop 3D model by Solidworks 29
3.2.3 Phase 3 29
3.2.3.1 Analysis by ANSYS 29
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3.2.4 Phase 4 29
3.2.4.1 Result 29
3.2.4.2 Discussion 29
3.3 Flow chart of analysis development
30 3.3.1 Step 1: Gather all dimension data of FDM nozzle
31 3.3.2 Step 2: Draw FDM 3D model by Solidworks
31 3.3.3 Transfer the 3D model from Solidworks to ANSYS
31 3.3.4 Run Static Structural Analysis
32 3.3.5 Run Modal Analysis
32 3.3.6 Step 7: Collect data of the result
32
CHAPTER 4: NOZZLE ANALYSIS 33
4.1 Introduction
33 4.2
3D Models 34
4.2.1 Assembly view 34
4.2.2 Exploded view 35
4.3 Bill of material
36 4.4
Defined load 39
4.5 Analysis by ANSYS
41 4.6.
Procedure to run Static Structural Analysis 42
4.7 Procedure to run Modal Analysis Analysis
52
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CHAPTER 5: RESULT AND DISCUSSION 55
5.1 Result static Structural analysis
55 5.1.1 Total deformation of statics structural analysis
55 5.1.2 Equivalent stress of static structural analysis
56 5.1.3 Factor of Safety of static structural analysis
57 5.1.4 Nozzle life estimation of static structural analysis
58 5.1.5 Damage test of static structural analysis
59 5.2
Result of Modal analysis 60
5.2.1 Analysis result for 20 kHz-30 kHz 60
5.2.2 Analysis result for 30 kHz-40 kHz 62
5.3 Discussion
64 5.3.1 Comparison of total deformation
64 5.3.2 Comparison of equivalent stress
65 5.3.2 Comparison of safety
66 5.4
Summary 67
CHAPTER 6: CONCLUSION AND RECOMMENDATION 68
