Analysis of applying ultrasonic system on FDM nozzle using ansys.
ANALYSIS OF APPLYING ULTRASONIC SYSTEM ON FDM
NOZZLE USING ANSYS
KHAIRUL FAHMI BIN ABDUL AZIZ
B051010184
UNIVERSITI TEKNIKAL MALAYSIA MELAKA 2014
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ANALYSIS OF APPLYING ULTRASONIC SYSTEM ON FDM
NOZZLE USING ANSYS
This report submitted in accordance with requirement of the UniversitiTeknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) (Hons.)
by
KHAIRUL FAHMI BIN ABDUL AZIZ B0501010184
880514-06-5433
FACULTY OF MANUFACTURING ENGINEERING 2014
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Analysis of Applying Ultrasonic System on FDM Nozzle Using ANSYS SESI PENGAJIAN: 2013/14 Semester 2
Saya KHAIRUL FAHMI BIN ABDUL AZIZ
Mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
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tujuan pengajian sahaja dengan izin penulis.
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4. **Silatandakan (√)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungimaklumat yang
berdarjahkeselamatanataukepentingan Malaysia
sebagaimana yang termaktubdalam AKTA RAHSIA RASMI 1972)
(Mengandungimaklumat TERHAD yang telahditentukanolehorganisasi/badan di manapenyelidikandijalankan)
AlamatTetap:
NO.43 LENGKOK SEMBILANG, TAMAN SEMBILANG,
13700 SEBERANG JAYA .PULAU PINANG. Tarikh: _________________________
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** JikaLaporan PSM ini SULIT atau TERHAD,
silalampirkansuratdaripadapihakberkuasa/organisasiberkenaandenganmenyatakansekalisebabdantempohlaporan PSM iniperludikelaskansebagai SULIT atau TERHAD.
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DECLARATION
I hereby, declared this report entitled “Analysis of Applying Ultrasonic System on FDM Nozzle Using ANSYS” is the results of my own research except as cited in references.
Signature : ……….
Author‟s Name : KHAIRUL FAHMI BIN ABDUL AZIZ
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i
ABSTRAK
Pemodelan Endapan Terlakur ialah sejenis Pembuatan pantas yang membolehkan seorang pereka atau jurutera menzahirkan bentuk yang dingini dengan hanya melukis suatu rekaan di dalam komputer. Ianya juga merupakan Pembuatan Pantas yang paling menjimatkan. Disebalik kelebihan itu, ianya mempunyai kelemahan paling ketara iaitu tidak dapat menghasilkan permukaan akhir dengan baik. Pengkaji sebelum ini telah mengeluarkan beberapa buah fikiran untuk mengatasi masalah ini. Antara buah fikiran yang telah mereka kemukakan ialah menyalurkan getaran tinggi daripada transduser ultrasonik kepada mesin Pemodelan Endapan Terlakur terutama pada bahagian muncung. Walau bagaimapun buah fikiran ini masih belum terbukti lagi kebenarannya. Projek ini bertujuan untuk mengkaji sama ada bahagian muncung Pemodelan Endapan Terlakur mampu untuk bertahan sekiranya disalurkan getaran yang tinggi. Projek ini telah dijalankan dengan menggunakan perisian Solidworks dan juga ANSYS. Solidworks digunakan untuk melukis model 3 dimensi dan ANSYS digunakan untuk menjalankan analisis statik dan juga getaran. Frekuensi yang digunakan ialah 20 kHz ke 30 kHz dan 30 kHz ke 40 kHz. Daripada keputusan analisis yang diperolehi Faktor Keselamatan paling rendah yang diperolehi ialah 18.8975. Dengan itu dapat disimpulkan bahawa muncung Pemodelan Endapan Terlakur tidak mempunyai masalah untuk menampung getaran yang disalurkan daripada transduser ultrasonik
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ABSTRACT
Fused Deposition Modeling is an Additive Manufacturing that allows a designer or engineer discloses a desired shape by simply drawing a design on the computer. It is also the most economical Additive Manufacturing. Despite these advantages, it has the biggest weakness that cannot produce a good surface finish. Researchers had previously released some ideas to solve this problem. Among the ideas that they put forward is to transmit high vibration from the ultrasonic transducer to the Fused Deposition Modelling machine, especially on the nozzle. However ideas have yet proven. This project aims to examine whether the nozzle Fused Deposition Modeling is able to withstand high vibration should be transmitted. This project was carried out using Solidworks and ANSYS software. Solidworks is used to draw 3 -dimensional model and ANSYS is used to perform static analysis and vibration. Frequencies applied are 20 kHz to 30 kHz and 30 kHz to 40 kHz. From the results of the analysis the lowest Factor of Safety obtained is 18.8975. Thus it can be concluded that the nozzle of Fused Deposition Modeling has no problem to withstand vibration transmitted from the ultrasonic transducer
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DEDICATION
Especially dedicated to my family, friends and companions for the endless support and understanding.
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ACKNOWLEDGEMENT
Foremost I would like to express my deepest appreciation to my supervisor Dr. Shajahan bin Maidin for his continuous support throughout my project, his patience, his motivation, enthusiasm and immense knowledge by helping me all the time in my project. The supervision and support that he gave truly help the progression and smoothness of the final year project. The co-operation is much indeed appreciated. Furthermore I would like to thank my parent, Mr. Abdul Aziz Bin Redzuan and Mrs. Mariam Binti Mansor, my adored siblings for their endless love and support.
In addition, I would like to thank to all lecturers and my friends because a lot of help in completing this study and give me motivation to accomplish this project. Thank you.
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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
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vi
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
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vii
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
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viii
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
6.1 Conclusion 68
6.2 Recommendation 69
REFERENCES 70
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ix
LIST OF TABLES
1.1 Gant chart for PSM 1 5
1.2 Gant chart for PSM 2 6
2.1 Advantage and disadvantage of SLA 14
2.2 Advantage and disadvantage of SLS 15
4.1 Parts description 36
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x
LIST OF FIGURES
2.1 Desire shape (left) and actual shape from AM machine 8
2.2 FDM process 17
2.3 Ultrasonic application and spectrum 19
2.4 Ultrasonic transducer 21
3.1 General project planning of this research 27
3.2 Flow chart of analysis development 30
4.1 Assembly view of FDM nozzle. 34
4.2 Exploded view of FDM nozzle. 35
4.3 ANSYS Workbench software 41
4.4 ANSYS software was turn on. 42
4.5 Static Structural appeared in Project Schematic 42
4.6 Browse option came out 43
4.7 File that need to analyze 43
4.8 Outline of engineering data 44
4.9 Data source display 44
4.10 General material options 45
4.11 Step to add material in analysis 45
4.12 Update project 46
4.13 Step ‘j‟ 46
4.14 Step to appear model 47
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xi
4.16 Step to sets Stainless Steel material 48
4.17 Step to sets magnesium alloy to the parts 48
4.18 Mesh setting 49
4.19 Mesh detail was set 49
4.20 Generate Mesh 50
4.21 Model after Mesh 50
4.22 Step to set force as parameter needed 51
4.23 Results needed were selected 51
4.24 Step to transfer data from Static Structural Analysis
to Modal Analysis 52
4.25 Range of the frequency was set 53
4.26 Total deformation was selected as result needed 53
4.27 All result needed were set 54
4.28 Solve the analysis 54
5.1 Total deformation of statics structural analysis 55 5.2 Equivalent stress from static structural analysis 56
5.3 FDM nozzle Factor of Safety 57
5.4 life estimation of FDM nozzle 58
5.5 Damage of FDM nozzle 5 59
5.6 Total deformation of FDM nozzle using frequency 20 kHz to 30 kHz. 60 5.7 Equivalent stress of FDM nozzle using frequency 20 kHz to 30 kHz 61 5.8 Total deformations when 30 kHz to 40 kHz frequency
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xii 5.9 Equivalent stress of FDM nozzle using frequency 30 kHz to 40 kHz 63 5.10 Bar chart of total deformation FDM nozzle for frequency
ranges 20 kHz to 30 kHz and 30 kHz to40 Khz 64 5.11 Bar chart of equivalent stress FDM nozzle for frequency
ranges 20 kHz to 30 kHz and 30 kHz to40 kHZ 65
5.12 Bar chart of Factor of Safety FDM nozzle for frequency
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xiii
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
AM - Additive Manufacturing CAD - Computer Aided Design CAE - Computer Aided Engineering FDM - Fused Deposition Modelling GPa - Giga Pascal
MPa - Mega Pascal mm - Milimeter
m/s2 - Metre per second square
N - Newton
RM - Rapid Manufacturing RP - Rapid Prototype SLA - Stereolithography
SLS - Selective Laser Sintering TMA - Thermal Mechanical Analysis
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CHAPTER 1
INTRODUCTION
This chapter briefly discusses about the aims, objectives and scope. Other than that it includes an overview of the project implementation.
1.1 Introduction
Peiponen et al. (2009), have previously mentioned, the quality surface finish of every product is very important in industry sector. The product surface can be improve by go through a sequence of finishing process. The quality of surface finish is important because it relate with friction, appearance, aesthetic value etc.
According to Rajendradarbar et al. (2013), Additive Manufacture (AM) is a “technology that allow user to get their desire shape of product by using CAD software”. The technology can construct complex shape of product nicely without face a lot of obstacles. Fused Deposition Modelling (FDM) is a type of additive manufacture. Brock et al. (2000), has previously mentioned that FDM produce their model by using semi molten plastic filament. This method is quite similar with MIG welding.
FDM is suitable to create a model with rough surface finish. Based on Rajendradarbar et al. (2013), the quality of surface finish is depending on parameter of the process. That's mean the parameter need to optimize in order to get good quality finish. By the way FDM always has problem with its surface finish. Lines
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2 seam appear on the surface model. Researchers have proposed a few of idea to overcome this problem. One of the ideas is applying chemical treatment to the FDM part but these techniques require high cost.
Ultrasonic is a technology that has been proved able to increase the quality of surface finish. The vibration that have been generate from ultrasonic will help the machine to produce good surface finish. The best thing about ultrasonic are it is not cause chemical reaction. Applying ultrasonic to FDM can increase the surface finish of the product but this statement does not prove yet. A few analysis need to be setup in order to prove this statement. However, without do simulation first the ultrasonic cannot be simply applied to the FDM. This is because it may be can destruct the machine‟s function itself. The experiment can separate by do the analysis component by component.
Nozzle is the essential component in FDM system because nozzle conditions give significant effect to the surface finish. Vibration analysis needs to be done first on FDM nozzle to make sure the nozzle withstand high frequency.
Nowadays simulation of new design is widely used. Based on Maria (1997), simulation of a system is a model that developed to test the system. She also has previously mentioned that simulation is used before an existing system is altered or a new system built, to reduce the chances of failure to meet specifications, to eliminate unforeseen bottlenecks, to prevent under or over utilization of resources, and to optimize system performance.
(CAD) is the computer software that uses to assist users to draw new design, do analysis or optimization of a design. There are many CAD software in the market such as Solidworks, CATIA, ANSYS, AutoCAD and others. One of CAD function is to do simulation of new product or new system. The advantages of using CAD are if there are some corrections it can be made easily. Beside that CAD standard can help user to transfer CAD data from computer to other system like from computer to the FDM machine.
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3 This project will use Solidworks to draw the 3D model of the system needed. After that ANSYS software will be use to run the simulation to get the result and effect by applying ultrasonic transducer to FDM machine.
1.2 Problem statement
FDM system is cheaper than others AM system however its surface finish is not so good like other expensive AM. A lot of ideas have been suggested from the researchers to solve this problem. One of the ideas is apply ultrasonic transducer to the FDM system. Applying ultrasonic may be suitable to solve this problem but the simulation needs to be done first to avoid any failure or damage to the real system, but before go to the whole system, the simulation to the FDM nozzle need to be done to know either the nozzle can stand with high frequency from ultrasonic.
1.3 Objective
a) To understand the operation of the Fused deposition modelling machine.
b) To learn to use ANSYS software.
c) To investigate whether FDM nozzle can withstand high frequency of ultrasound.
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1.4 Scope of project
This project focuses about the impact of high frequency of ultrasound to FDM nozzle. The analysis run by ANSYS and 3D model developed by Solidworks. The nozzle dimension is same with FDM nozzle in FDM laboratory of Fakulti Kejuruteraan Pembuatan, UTeM. The raw materials of the nozzle component are from stainless steel and magnesium alloy. This project also focuses on mechanical properties. Others properties like thermal properties and others are neglect.
1.5 Activity planning
Activity planning is the plan to follow to accomplish this project. Table 1.1 and table 1.2 shows the Gantt chart for this project. The Gantt chart must be follow to ensure this project is still on track to avoid this project break the date line. Time given to accomplish every task is depend on constrain to do that task.
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CHAPTER 2
LITERATURE REVIEWS
2.1 Additive Manufacturing
Additive Manufacture (AM) can be defined as “technology that allow user to get the product with their desire shape by using CAD software”. Without facing many obstacles the technology can built the product with complex shape nicely (Rajendradarbar, 2013).
Stucker (2011), has previously mentioned that Additive manufacturing techniques are the collection of manufacturing processes that join materials to make physical 3D objects directly from virtual 3D computer data. These processes typically build up parts layer by layer, as opposed to subtractive manufacturing methodologies, which create 3D geometry by removing material in a sequential manner. After more than 20 years of confusing terminology, in 2009, the ASTM International F42 Committee on Additive Manufacturing Technologies defined additive manufacturing as the “process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.” These technologies were also known as rapid prototyping, additive layer manufacturing, solid freeform fabrication, direct digital manufacturing additive fabrication, and other similar technology names over the years. In the technical community, an international agreed has coalesced around the use of “additive manufacturing,” whereas in the popular press the technologies are known as “3D printing.
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2 seam appear on the surface model. Researchers have proposed a few of idea to overcome this problem. One of the ideas is applying chemical treatment to the FDM part but these techniques require high cost.
Ultrasonic is a technology that has been proved able to increase the quality of surface finish. The vibration that have been generate from ultrasonic will help the machine to produce good surface finish. The best thing about ultrasonic are it is not cause chemical reaction. Applying ultrasonic to FDM can increase the surface finish of the product but this statement does not prove yet. A few analysis need to be setup in order to prove this statement. However, without do simulation first the ultrasonic cannot be simply applied to the FDM. This is because it may be can destruct the machine‟s function itself. The experiment can separate by do the analysis component by component.
Nozzle is the essential component in FDM system because nozzle conditions give significant effect to the surface finish. Vibration analysis needs to be done first on FDM nozzle to make sure the nozzle withstand high frequency.
Nowadays simulation of new design is widely used. Based on Maria (1997), simulation of a system is a model that developed to test the system. She also has previously mentioned that simulation is used before an existing system is altered or a new system built, to reduce the chances of failure to meet specifications, to eliminate unforeseen bottlenecks, to prevent under or over utilization of resources, and to optimize system performance.
(CAD) is the computer software that uses to assist users to draw new design, do analysis or optimization of a design. There are many CAD software in the market such as Solidworks, CATIA, ANSYS, AutoCAD and others. One of CAD function is to do simulation of new product or new system. The advantages of using CAD are if there are some corrections it can be made easily. Beside that CAD standard can help user to transfer CAD data from computer to other system like from computer to the FDM machine.
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3 This project will use Solidworks to draw the 3D model of the system needed. After that ANSYS software will be use to run the simulation to get the result and effect by applying ultrasonic transducer to FDM machine.
1.2 Problem statement
FDM system is cheaper than others AM system however its surface finish is not so good like other expensive AM. A lot of ideas have been suggested from the researchers to solve this problem. One of the ideas is apply ultrasonic transducer to the FDM system. Applying ultrasonic may be suitable to solve this problem but the simulation needs to be done first to avoid any failure or damage to the real system, but before go to the whole system, the simulation to the FDM nozzle need to be done to know either the nozzle can stand with high frequency from ultrasonic.
1.3 Objective
a) To understand the operation of the Fused deposition modelling machine. b) To learn to use ANSYS software.
c) To investigate whether FDM nozzle can withstand high frequency of ultrasound.
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4
1.4 Scope of project
This project focuses about the impact of high frequency of ultrasound to FDM nozzle. The analysis run by ANSYS and 3D model developed by Solidworks. The nozzle dimension is same with FDM nozzle in FDM laboratory of Fakulti Kejuruteraan Pembuatan, UTeM. The raw materials of the nozzle component are from stainless steel and magnesium alloy. This project also focuses on mechanical properties. Others properties like thermal properties and others are neglect.
1.5 Activity planning
Activity planning is the plan to follow to accomplish this project. Table 1.1 and table 1.2 shows the Gantt chart for this project. The Gantt chart must be follow to ensure this project is still on track to avoid this project break the date line. Time given to accomplish every task is depend on constrain to do that task.
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5 Table 1.1 : Gant chart for PSM 1
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6 Table 1.2 : Gant chart for PSM 2
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CHAPTER 2
LITERATURE REVIEWS
2.1 Additive Manufacturing
Additive Manufacture (AM) can be defined as “technology that allow user to get the product with their desire shape by using CAD software”. Without facing many obstacles the technology can built the product with complex shape nicely (Rajendradarbar, 2013).
Stucker (2011), has previously mentioned that Additive manufacturing techniques are the collection of manufacturing processes that join materials to make physical 3D objects directly from virtual 3D computer data. These processes typically build up parts layer by layer, as opposed to subtractive manufacturing methodologies, which create 3D geometry by removing material in a sequential manner. After more than 20 years of confusing terminology, in 2009, the ASTM International F42 Committee on Additive Manufacturing Technologies defined additive manufacturing as the “process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.” These technologies were also known as rapid prototyping, additive layer manufacturing, solid freeform fabrication, direct digital manufacturing additive fabrication, and other similar technology names over the years. In the technical community, an international agreed has coalesced around the use of “additive manufacturing,” whereas in the popular press the technologies are known as “3D printing.