Mechanical Properties Of Powder-Based Part Produced By 3 Dimensional Printer Machine.
ii
“I hereby declare that this project report is written by me and is my own effort and that
no part has been plagiarized without citation”
Signature
: ………………………………………..
Name of Writer
: ………………………………………..
Date
: ……………………………………….
iii
DEDICATION
To my parents, my supervisor and friends.
iv
ACKNOLEDGEMENT
First, author would like to express my gratitude to the supervisor Puan Siti Hajar
Bt Sheikh Md Fadzullah for her encouragement and support. Also thank you for
guidance along this project.
I also would like to thank to Puan Ruzy Haryati Bt Hambali for her support and
advise. For En. Fairuz who has given his time to teach me about the machine.
Lastly but not least this appreciation also wish to anyone whose was involved for
help this project. I hope that that this report will become source of references to students
in future.
v
ABSTRACT
Rapid Prototyping (RP) is referred to as a class of technology that can
automatically build a physical model from (CAD) data. One of the rapid prototyping
technologies is explored via Three Dimensional Printing (3DP) Machine developed by
the Massachusetts Institute of Technology and license to Z Corporation, which is use
powder-based material. The capability of Three Dimensional Printing (3DP) are speedy
fabrication and low material cost. There were three types of specimen dimension, which
was design, and the Compression Testing as per ASTM D695 was done to investigate
the mechanical properties, which is Prism 1 (12.7x12.7x25.4) mm, Prism 2 (15x15x30)
mm and dog-bone (5 specimens for each type). The 3DP machine that was used to
produce the parts is ZPrinter 310 Plus and the material that the machine used is ZP130
for the powder and Zb58 for the binder. From the results that was obtained from the
compression testing, dog-bone specimen obtained the highest Compressive Strength at
4.43±0.623 MPa and also the highest Modulus of Elasticity at 1.71±0.143 GPa. In
comparison with prism 1 of 2.96±2.21 MPa for Compressive Strength and 1.26±0.259
GPa for Modulus of Elasticity and for prism 2 of 2.30±0.931 MPa for Compressive
Strength and 1.37±0.195 GPa for Modulus of Elasticity. From the results that were
analyzed, it can be concluded that the smallest cross-section area produce the highest
compressive strength, this is because binder is highly concentrated and absorbed into the
specimen.
vi
ABSTRAK
Rapid Prototyping
merujuk kepada suatu bidang teknologi masa kini yang
mampu untuk menghasilkan model fizikal secara automatik berdasarkan data daripada
lukisan terbantu computer. Cepat menghasilkan produk dan kos bahan adalah rendah
merupakan kunci kepada kebaikan-kabaikan penggunaan teknologi ini. Tesis ini
bertujuan untuk mengkaji sifat-sifat mekanikal terutamanya daripada aspek mampatan
bagi sesuatu produk berasaskan powder-based yg dihasilkan melalui mesin 3DPrinter.
Penyelidikan ini melibatkan tiga jenis specimen iaitu lima unit bagi setiap specimen.
Prism 1 yang mempunyai dimensi 12.7mm x 12.7mm x 25.4 dan Prism 2 berdimensi
15mm x 15mm x30mm dan spesimen yang ketiga berbentuk dog-bone adalah merujuk
kepada Ujian Mampatan ASTM D695. Mesin jenis ZPrinter 310 Plus, bahan asas Zp30,
dan binder Zb58 adalah peralatan-peralatan yang terlibat secara langsung di dalam
penyelidikan ini. Berdasarkan keputusan yang diperolehi, specimen jenis dog-bone
mempunyai nilai kekuatan mampatan yang tertinggi iaitu 4.43±0.623MPa modulus
keanjalan dan 1.71±0.143GPa. Seterusnya,
diikuti
dengan Prism
1 dengan
2.96±2.21MPa nilai mampatan dan 1.26±0.259GPa untuk nilai modulus keanjalan.
Untuk Prism 2, nilai kekuatan mampatan adalah 2.30±0.931MPa and 1.37±0.195GPa
untuk Modulus keanjalan. Setelah kesemua keputusan yang diperolehi dianalisa,
kesimpulan yang dapat dibuat adalah semakin kecil keratan rentas, akan menghasilkan
nilai kekuatan mampatan yang tinggi kerana binder banyak diserap kedalam spesimen.
vii
LIST OF TABLE
NO.
TITLE
1.0
Gantt Chart for the Research Activity in this Project.
5
2.1
Comparison of Rapid Prototyping
19
2.2
Rule of Thumb Miniature Feature Size
28
2.3
Type of 3D Printer
37
2.4
General Definition of Mechanical Properties
38
2.5
RapidSteel properties
38
2.6
Copper polyamide properties
40
2.7
Properties of bronze-based sintered powder and manufacturing
time and cost
2.8
PAGE
41
Processing data and properties of Ref. and prepared by 3D-Printing
Al2O3/Cu-alloy composites
47
3.0
Dimension for each specimen
50
3.1
Identification of Chemical Substance and Company
50
3.2
Composition / information of Ingredients
51
3.3
Physical and Chemical Properties
52
3.4
Stability and reactivity
52
3.5
Identification of Chemical Substance and Company
53
3.6
Composition / information of Ingredients
53
3.7
Physical and Chemical Properties
54
viii
3.8
Stability and reactivity
55
3.9
Technical Specification for Zprinter 310 Plus
59
3.10
Dimension for each specimen
60
4.1
Experimental and Theoretical value of Yield Strength for
different type of specimen
64
4.2
Compressive Strength data from Experiment and Theoretical
68
4.3
Modulus of Elasticity data for Experiment and Theoretical
71
5.0
Experimental Result for Three different Type of Specimens
74
5.1
Table for Theoretical
75
ix
LIST OF FIGURE
NO.
TITLE
2.1
Schematic diagram of stereolithography
12
2.2
Schematic diagram of laser sintering
13
2.3
Schematic diagram of FDM
14
2.4
Schematic diagram of 3D printing
14
2.5
Schematic diagram of laminated object manufacturing
15
2.6
Stairstepping
23
2.7
Surface finish for each type of RP
24
2.8
Surface Finish of Sculpture
25
2.9
Three-dimensional printing process
29
2.10
Gas-atomized (left) and water-atomized (right) 316L stainless
steel powder
2.11
PAGE
32
Ink-jet printed, two-dimensional ZrO2 structure with 170 μm
resolution. The distance between the outer vertical surfaces of
adjacent walls is approximately 1 mm
2.12
33
Three-dimensional structures fabricated by direct ceramic
ink-jet printing. The optical image is shown on the left; the
SEM scan showing details is shown on the right
34
x
3.0
Overview of research methodology
45
3.1
Flow process for the research design
46
3.2
Shape and dimensions specimen for compression test
48
3.3
Shape and dimensions specimen for compression test
49
3.4
Shape and dimensions specimen for compression test
55
3.5
3D Printer Machine
56
3.6
Flow Process of 3DP Processing
57
3.7
The process of 3D printer
60
3.8
Compression testing machine
60
4.1
Comparison chart for mean value of Yield Strength for
experiment and theory
65
4.2
Graph of Load versus Strain for each specimen.
66
4.3
Figure before and after compression testing
67
4.4
Chart for Mean Value of Compressive Strength
69
4.5
Experimental and Theoretical Mean Value of Compressive Strength
70
4.6
Mean Value of Compesssive Modulus each specimen
72
4.7
Mean Value of Compressive Modulus for Experimental and theoretical.
72
5.1
Type of the build direction.
77
5.2
Direction of the compression load for each type of build direction.
77
5.3
Figure before and after compression testing.
78
xi
TABLE OF CONTENT
CHAPTER
CHAPTER 1
CHAPTER 2
INDEX
PAGE
DECLARATION
ii
DEDICATION
iii
ACKNOLEDGEMENT
iv
ABSTRACT
v
ABSTRAK
vi
LIST OF TABLE
vii
LIST OF FIGURE
ix
TABLE OF CONTENT
xi
INTRODUCTION
1.1
Rapid Prototyping
2
1.2
Three Dimensional Printer
4
1.3
Aim of Work
4
1.4
Problem Statement
4
1.5
Planning Execution
5
LITERATURE REVIEW
2.1
Rapid Prototyping
6
2.1.1
Type of RP technique
12
2.1.2
Basic Process
15
xii
2.1.3
2.2
2.3
2.4
Comparison of RP Technique
17
Three Dimensional Printer
27
2.2.1
29
Basic Process
Material
30
2.3.1
Powder Based
31
2.3.1.1 Metal Powder
31
2.3.1.2 Ceramic Powder
33
Mechanical Properties
36
2.4.1
37
Mechanical Properties of Part Produce
from Metal Powder
2.4.2 Mechanical Properties of Part Produce
42
from Polymer Powder
2.4.3
Mechanical Properties of Part Produce
43
from Ceramic Powder
CHAPTER 3
METHODOLOGY
3.1
Research Design
44
3.2
Design of Test Specimen
46
3.2.1
Design of experiment
47
3.2.2
Design of Test Specimen Via
47
SolidWorks
3.3
Raw Material
49
3.4
3D Pinter
54
3.4.1
56
3.5
Processing
Mechanical Testing
58
3.5.1
58
Compression Test as per ASTM D695
3.5.1.1 Equipment/ Testing Apparatus
59
3.5.1.2 Testing Parameter
60
xiii
CHAPTER 4
RESULT AND ANALYSIS
4.1
Stress-strain Relationship of Part Produce from
63
3-D Printer under Compression Force
4.2
Compressive Strength of Part Produce from
68
3-D Printer
4.3
Compressive Modulus of Part Produce from
70
3-D Printer
CHAPTER 5
DISCUSSION
73
CHAPTER 6
CONCLUSION
80
CHAPTER 7
SUGGESSTION AND RECOMMENDATION
81
FOR FUTURE WORKS
REFFERENCES
82
BIBLIOGRAFI
85
APPENDIX
87
1
CHAPTER I
INTRODUCTION
Rapid Prototyping (RP) is a technology that provides the ability to build or
fabricate prototypes for initial design of a product. There are various materials can be
used in producing the prototypes needed, which depends on the RP machine itself. For
3D-Printer Machine, it actually can be simplified as a commercial RP process. Various
process parameters can be found in 3D-printer which affects the character of RP parts;
including build direction, layer thickness, temperature and so on. Layer thickness
actually refers to the thickness of each part being produced by the 3D-Printer Machine.
Before any products become a product that can be use in human life, one sample
or prototype required as a specimen. This is because the sample will used to allow for
demonstration, evaluation or testing for the proposed product. The technology that used
to make the prototype is define as Rapid Prototyping (RP) and usually come first before
a specific mold tool and jigs are design. For make prototyping traditionally required skill
of employee, time and cost. These three causes usually applied for cutting, bending,
shaping and assembly the part that needed.
The procedure was often iterative, with a series of prototypes being built to test
various options. For many applications, this process has been revolutionized by a
relatively recent technology known as layer manufacturing or Solid Freeform
Fabrication(SFF) which is any part from any shape, can be produced in a single process
2
by adding successive layers of material. Usually mold, jigs and die are also include the
quickly fabrication of the tools required for mass production. Now, there are many
different manufacturing process have develop using an increasing the range of material
[1,].
1.1
Rapid Prototyping
Rapid Prototyping (RP) is referred to as a class of technology can automatically
build a physical model from Computer-Aided Design (CAD) data. This technology
make designer quickly create prototypes of their design, although just two dimension
pictures [1, 2, 3, 5, 7, 9,10]. Prototype can also be used in design testing. Other than
that, RP also can be use to make tooling and any production part. RP is usually best
manufacturing process for small production runs and complicated object.
Most
producing prototype take shortly time, but the time that required depends on the size and
the complexity of the object.
This process rather consumes more time make the
prototype but still better than conventional method such as machining. Rapid
prototyping system is a technology that emerges in 1980s. During the modern concept of
Rapid prototyping was conceived and developed; actually the origin of this technology
is back to the 1890s [1]. This is some of the most popular and commonly used RP
technique [3,10]:
i.
Selective laser sintering (SLS)
ii.
Fused Deposition Modeling (FDM)
iii.
Stereolithography (SLA)
iv.
Multi Jet Modeling (MJM)
v.
Laminated Object Manufacturing (LOM)
vi.
Electron Beam Melting (EBM)
vii.
3D Printing (3DP)
viii.
Objet PolyJet Modeling
3
1.2
Three -dimensional Printer
Three-Dimensioning printing refers to a category of rapid technology which is
converting a virtual 3D model to become a physical object. Typically, 3D printer is an
extremely flexible system, capable of creating part of any shape using any material
including ceramics, metals, polymers and composites. 3D printer also generally faster
and easier to use than other additive technologies. Three-dimensional printing (3DP)
developed by the Massachusetts Institute of Technology and licensed to Z Corporation
of Burlington, Massachusetts. The material usually use in this system is limited to two
choices: plaster or starch.
Usually the material that is recommended is the plaster based because it is more
durable and gives better resolution. Starch should be used if need making investment
mold. After finish printing the part, it should be infiltrated. Infiltrants that are used to
wax includes cyanoacrylate (superglue) and Z Max epoxy [4].
A unique capability of three-dimensional printing is the ability to produce
multicolored parts. A part’s color is determined by dyes added to the liquid binder.
Almost any color is possible. Each layer, in essence, is like a full-color image printed on
a flat sheet of paper by an ink-jet printer
Three dimensional printing offers the advantages of speedy fabrication and low
materials cost. In fact, it's probably the fastest of all RP methods. Recently color output
has also become available. However, there are limitations on resolution, surface finish,
part fragility and available materials. The closest competitor to this process is probably
fused deposition modeling [2,10].
4
1.3
Aim of Works
The objective in this project is:
To design and fabricate part from powder- based material using 3D printer.
To investigate the mechanical properties of part produced.
The scope in this project is:
To design a part from powder- based material used in rapid prototyping.
To fabricate part using 3d printer machine.
To investigate the mechanical properties of part including compression test as
per ASTM D695.
1.4
Problem Statement
This research is dedicated to the study of particularly for compression behavior
of part which produces using 3D-Printer Machine. From the literature review, many
researches reported about the specimen dimension, technical specification of machine
but very few resources have reported about mechanical properties of powder-based part
produced from the 3D Printer.
1.5
Planning and Execution
Table 1 below depicts the research activity that is carried out throughout the
project. The first four months is dedicated to the literature review and design of the
experiment
(DOE)
that
cover
the
research
methodology.
5
Table 1.0: Gantt Chart for the Research Activity in this Project.
Research
Activity/Time
W1
W2
W3
W4
W5
W6
PSM 1
Problem Statement
Literature Review
Rapid Prototyping
3D Printer
Raw Material used
Mechanical
Properties
Methodology
Experimental review
Research Design
DOE
RP Process
Mechanical Testing
Design of Test
Specimen
Report Writing
Submission Report
PSM 2
Literature Review
RP/3D Printer
Raw Material
Mechanical
Properties
Methodology
Produce Specimen
Procedure of
Mechanical Testing
Mechanical testing
Compression Test
Result & Findings
Report Writing
Submission report
W7
W8
W9
W10
W11
W12
W13
6
CHAPTER II
LITERATURE REVIEW
2.1
Rapid Prototyping
Rapid Prototyping (RP) refers to a group of technologies that can fabricate
physical, three dimensional part of arbitrary shape directly from Computer Aided Design
(CAD) and Computer Aided Manufacturing (CAM) by fully automated, fast and highly
flexible process [2, 5, 7, 8, 9, 10]. According to the Wohler Report (2004), Rapid
Prototyping refers to fabricate a physical model of a design using digital driven, additive
processes. RP also produce model very quickly from 3D CAD data, CT and MRI scans,
and data from 3D digitizing system. This means, Rapid Prototyping method can save the
processing time and also save cost producing the prototype than using conventional
technique for fabricating physical model which can be more expensive and also time
consuming which may take a few days or even weeks [2, 5].
Rapid Prototyping was emerged in 1980’s, where the high technology was
conceived, developed and promote in 1980’s. 1890’s is the date of the origin technology.
For the early history for rapid prototyping, it’s also known a layered manufacturing.
This is because of the concept for building something using layer by layer at
least two technical areas: topography and photosculpture. In that time, the method used
7
to produce tool or even prototype and usually the product that have produce in small
quantities [2].
This technology allow designer quickly create prototypes of their design,
although just two dimension pictures. Designer will makes the prefect visual aids for
show their ideas to their co-workers and also to customers. Prototype usually numerous
use such as, it can be use in design testing. Other than that, RP also can be use to make
tooling and any production part. RP is usually best manufacturing process for small
production runs and complicated object. Most producing prototype take shortly time,
but the time that required depends on the size and the complexity of the object.
RP system has it own advantages such as; prototype that required can build even
though the prototype has a complex shape. It also builds the prototype without setting
the arrangement of the machine. Besides that, RP also build the prototype using multiple
materials by available technique. Other than that, RP has reduced time to market. Cut
trial cost and improved the quality of the product.
RP have become an important part of the product development process. By using
RP has time taken can be reduced, cut cost and improve the quality of the product. This
means, RP allowed user do and fabricate the design and prototype to verify before they
involve in the expensive tooling and fabrication of mass production. Below are several
type of application in education and industry [2].
i.
Application in Product Development
In this new era of global for providing product and service, RP
technology become one of the medium that make the process become
easier. This is because all the company involve in product development
and manufacturing will face with the competition to bring the product to
market faster, cheaper and also with high quality functioning. In this
problem, RP is the best solution for the problem that help all companies
by reduce the cycle of product development and also during making the
8
design for making improvement of the product. The most application can
be dividing into three major categories:
a) Prototype Design Evaluation
b) Prototype for Function Verification
c) Prototype for Manufacturing Process Validation
ii.
Application in Reverse Engineering
Reverse Engineering is science by taking the physical model and produce
it surface geometry in 3D data file on CAD file. RE is the faster way to
get 3D data into any computer system. The example for this application is
situation includes hand made prototypes, craft work, dental application
and reproduction of old engineering object.
iii.
Application in Casting and Pattern Making
This application is important for casting and pattern making. Casting
allows fabricate complex shape but for the simple shape machining can
be used.
iv.
Application in Rapid Tooling
According to the rapid solution web, Rapid tooling is using a rapid
prototype, either indirectly or directly, as a tooling pattern for creating a
mold. Rapid tooling techniques enable you to have molds with the
correct material at a substantially reduced cost in a fraction of the time it
takes to produce parts from production tooling processes. The greater the
complexity of the part, is the greater the benefits of cost and time.
v.
Application in Medical
Application in medical is one of the most successful applications for
rapid manufacturing. For the example this application is used to the
production of customized hearing aids. This is because every ear is
9
different, and the size of the parts makes it possible to fabricate the
products in large, economical batches with existing equipment.
vi.
Application in Rapid Manufacturing
a. In Rapid manufacturing, there are still having a lot of challenges for the
limitation of speed, material and accuracy. But by using the rapid
prototyping
technology
most
of
the
companies
show
the
successfully[2,3,7,9]
According to Rochus, et.al (2007) their article was reported rapid prototyping
and manufacturing are known to be destructive technologies. Everyday industry used of
this method has increase rapidly. The principal of this technology of manufacturing parts
is layer by layer starting from liquid, paste or powder. After the material is deposited,
the selecting surface is treated according to a process define by the chosen technique in
order to solidify a cross section of the final component. This process are applied for
prototyping, small series, injection moulds manufacturing, mock-ups and also used in
several engineering sectors. In their article also state the general description for the rapid
prototyping technique such as, Stereolithography (SLA), Selective Laser Sintering (SLS)
and Jet Based Technology. The start with a 3D CAD model, then the model need to
convert to the stereolithography (STL) format. Only this format can be read by the
machine. This is because the format will change dividing the model into layer form. By
dividing the object into the layer form, the machine will printed the object layer by layer
according to the STL format. This process is continuously until the layer becomes an
object.
It is reported from in their article, rapid prototyping is a innovative technology
develop rapidly and very useful for industry. The aim of this technology is to produce
prototype relatively quickly. Most the RP system is now commercially available. There
are three type of system that can be classified according to the material used which is
powder based, resin based and sheet based. For powder based, the RP process includes
the Selective Laser Sintering (SLS) and 3D Printing process. Resin based process such
10
as Stereolithography (SLA) and the laminated sheet based process included the
Laminated Object Manufacturing (LOM) process. Generally all the principal of process
are similar but the things that make the technique different are the materials that use to
make prototyping. In this paper also mention the advantage of this technology such a
reducing time and cost. This is because, all the process will make the prototype in the
short time than the traditionally method. And also can produce more prototypes in one
time. Besides that, this technology make the cost reduce by making the prototype in
exactly as the real one. But, this technology has the limitation such as the quality and
accuracy. But not all the system of RP has this problem [Choi,et al (2003)].
According to Durham. (2003) Rapid Prototyping is very useful in industry. This
is because RP is a powerful tool to reducing time to market and it also improving quality
and reducing cost. He also said the challenge is during selecting the suitable process that
need to use. During making decision for what process that need to choose, the important
thing that needs to consider is combination with the intended material. This is because;
selecting a process without considering the material will yield the questionable result. In
his article also state the RP process that usually used in industry which is,
Stereolithography (SLA), Selective Laser Sintering (SLS) and also PolyJet. In this
article also mention comparison the process as the material available for each.
Stereolithography (SLA) process is used material in liquid resin. The process is using
ultraviolet laser to solidify the material. Although the SLA is limited in its range of
applicable material, it is suitable for conceptual visualization. Selective Laser Sintering
(SLS), the material is from powder material. The SLS process create the object by
heating the powder using heat from a carbon dioxide laser fuses (sinter). The advantage
for this process is more widely using in industry and also suitable for function analysis.
Hatsopoulos, (2000) wrote that Rapid Prototyping introduces a method that is
called “3D Printing”. Before this, the model making take too much time and the cost is
high. Also the technique is always limited for use. But it is less expensive and faster
when using 3D printing method. From this, this technology give the designer better
access to model, which is provide the freedom to make many more of model. This
“I hereby declare that this project report is written by me and is my own effort and that
no part has been plagiarized without citation”
Signature
: ………………………………………..
Name of Writer
: ………………………………………..
Date
: ……………………………………….
iii
DEDICATION
To my parents, my supervisor and friends.
iv
ACKNOLEDGEMENT
First, author would like to express my gratitude to the supervisor Puan Siti Hajar
Bt Sheikh Md Fadzullah for her encouragement and support. Also thank you for
guidance along this project.
I also would like to thank to Puan Ruzy Haryati Bt Hambali for her support and
advise. For En. Fairuz who has given his time to teach me about the machine.
Lastly but not least this appreciation also wish to anyone whose was involved for
help this project. I hope that that this report will become source of references to students
in future.
v
ABSTRACT
Rapid Prototyping (RP) is referred to as a class of technology that can
automatically build a physical model from (CAD) data. One of the rapid prototyping
technologies is explored via Three Dimensional Printing (3DP) Machine developed by
the Massachusetts Institute of Technology and license to Z Corporation, which is use
powder-based material. The capability of Three Dimensional Printing (3DP) are speedy
fabrication and low material cost. There were three types of specimen dimension, which
was design, and the Compression Testing as per ASTM D695 was done to investigate
the mechanical properties, which is Prism 1 (12.7x12.7x25.4) mm, Prism 2 (15x15x30)
mm and dog-bone (5 specimens for each type). The 3DP machine that was used to
produce the parts is ZPrinter 310 Plus and the material that the machine used is ZP130
for the powder and Zb58 for the binder. From the results that was obtained from the
compression testing, dog-bone specimen obtained the highest Compressive Strength at
4.43±0.623 MPa and also the highest Modulus of Elasticity at 1.71±0.143 GPa. In
comparison with prism 1 of 2.96±2.21 MPa for Compressive Strength and 1.26±0.259
GPa for Modulus of Elasticity and for prism 2 of 2.30±0.931 MPa for Compressive
Strength and 1.37±0.195 GPa for Modulus of Elasticity. From the results that were
analyzed, it can be concluded that the smallest cross-section area produce the highest
compressive strength, this is because binder is highly concentrated and absorbed into the
specimen.
vi
ABSTRAK
Rapid Prototyping
merujuk kepada suatu bidang teknologi masa kini yang
mampu untuk menghasilkan model fizikal secara automatik berdasarkan data daripada
lukisan terbantu computer. Cepat menghasilkan produk dan kos bahan adalah rendah
merupakan kunci kepada kebaikan-kabaikan penggunaan teknologi ini. Tesis ini
bertujuan untuk mengkaji sifat-sifat mekanikal terutamanya daripada aspek mampatan
bagi sesuatu produk berasaskan powder-based yg dihasilkan melalui mesin 3DPrinter.
Penyelidikan ini melibatkan tiga jenis specimen iaitu lima unit bagi setiap specimen.
Prism 1 yang mempunyai dimensi 12.7mm x 12.7mm x 25.4 dan Prism 2 berdimensi
15mm x 15mm x30mm dan spesimen yang ketiga berbentuk dog-bone adalah merujuk
kepada Ujian Mampatan ASTM D695. Mesin jenis ZPrinter 310 Plus, bahan asas Zp30,
dan binder Zb58 adalah peralatan-peralatan yang terlibat secara langsung di dalam
penyelidikan ini. Berdasarkan keputusan yang diperolehi, specimen jenis dog-bone
mempunyai nilai kekuatan mampatan yang tertinggi iaitu 4.43±0.623MPa modulus
keanjalan dan 1.71±0.143GPa. Seterusnya,
diikuti
dengan Prism
1 dengan
2.96±2.21MPa nilai mampatan dan 1.26±0.259GPa untuk nilai modulus keanjalan.
Untuk Prism 2, nilai kekuatan mampatan adalah 2.30±0.931MPa and 1.37±0.195GPa
untuk Modulus keanjalan. Setelah kesemua keputusan yang diperolehi dianalisa,
kesimpulan yang dapat dibuat adalah semakin kecil keratan rentas, akan menghasilkan
nilai kekuatan mampatan yang tinggi kerana binder banyak diserap kedalam spesimen.
vii
LIST OF TABLE
NO.
TITLE
1.0
Gantt Chart for the Research Activity in this Project.
5
2.1
Comparison of Rapid Prototyping
19
2.2
Rule of Thumb Miniature Feature Size
28
2.3
Type of 3D Printer
37
2.4
General Definition of Mechanical Properties
38
2.5
RapidSteel properties
38
2.6
Copper polyamide properties
40
2.7
Properties of bronze-based sintered powder and manufacturing
time and cost
2.8
PAGE
41
Processing data and properties of Ref. and prepared by 3D-Printing
Al2O3/Cu-alloy composites
47
3.0
Dimension for each specimen
50
3.1
Identification of Chemical Substance and Company
50
3.2
Composition / information of Ingredients
51
3.3
Physical and Chemical Properties
52
3.4
Stability and reactivity
52
3.5
Identification of Chemical Substance and Company
53
3.6
Composition / information of Ingredients
53
3.7
Physical and Chemical Properties
54
viii
3.8
Stability and reactivity
55
3.9
Technical Specification for Zprinter 310 Plus
59
3.10
Dimension for each specimen
60
4.1
Experimental and Theoretical value of Yield Strength for
different type of specimen
64
4.2
Compressive Strength data from Experiment and Theoretical
68
4.3
Modulus of Elasticity data for Experiment and Theoretical
71
5.0
Experimental Result for Three different Type of Specimens
74
5.1
Table for Theoretical
75
ix
LIST OF FIGURE
NO.
TITLE
2.1
Schematic diagram of stereolithography
12
2.2
Schematic diagram of laser sintering
13
2.3
Schematic diagram of FDM
14
2.4
Schematic diagram of 3D printing
14
2.5
Schematic diagram of laminated object manufacturing
15
2.6
Stairstepping
23
2.7
Surface finish for each type of RP
24
2.8
Surface Finish of Sculpture
25
2.9
Three-dimensional printing process
29
2.10
Gas-atomized (left) and water-atomized (right) 316L stainless
steel powder
2.11
PAGE
32
Ink-jet printed, two-dimensional ZrO2 structure with 170 μm
resolution. The distance between the outer vertical surfaces of
adjacent walls is approximately 1 mm
2.12
33
Three-dimensional structures fabricated by direct ceramic
ink-jet printing. The optical image is shown on the left; the
SEM scan showing details is shown on the right
34
x
3.0
Overview of research methodology
45
3.1
Flow process for the research design
46
3.2
Shape and dimensions specimen for compression test
48
3.3
Shape and dimensions specimen for compression test
49
3.4
Shape and dimensions specimen for compression test
55
3.5
3D Printer Machine
56
3.6
Flow Process of 3DP Processing
57
3.7
The process of 3D printer
60
3.8
Compression testing machine
60
4.1
Comparison chart for mean value of Yield Strength for
experiment and theory
65
4.2
Graph of Load versus Strain for each specimen.
66
4.3
Figure before and after compression testing
67
4.4
Chart for Mean Value of Compressive Strength
69
4.5
Experimental and Theoretical Mean Value of Compressive Strength
70
4.6
Mean Value of Compesssive Modulus each specimen
72
4.7
Mean Value of Compressive Modulus for Experimental and theoretical.
72
5.1
Type of the build direction.
77
5.2
Direction of the compression load for each type of build direction.
77
5.3
Figure before and after compression testing.
78
xi
TABLE OF CONTENT
CHAPTER
CHAPTER 1
CHAPTER 2
INDEX
PAGE
DECLARATION
ii
DEDICATION
iii
ACKNOLEDGEMENT
iv
ABSTRACT
v
ABSTRAK
vi
LIST OF TABLE
vii
LIST OF FIGURE
ix
TABLE OF CONTENT
xi
INTRODUCTION
1.1
Rapid Prototyping
2
1.2
Three Dimensional Printer
4
1.3
Aim of Work
4
1.4
Problem Statement
4
1.5
Planning Execution
5
LITERATURE REVIEW
2.1
Rapid Prototyping
6
2.1.1
Type of RP technique
12
2.1.2
Basic Process
15
xii
2.1.3
2.2
2.3
2.4
Comparison of RP Technique
17
Three Dimensional Printer
27
2.2.1
29
Basic Process
Material
30
2.3.1
Powder Based
31
2.3.1.1 Metal Powder
31
2.3.1.2 Ceramic Powder
33
Mechanical Properties
36
2.4.1
37
Mechanical Properties of Part Produce
from Metal Powder
2.4.2 Mechanical Properties of Part Produce
42
from Polymer Powder
2.4.3
Mechanical Properties of Part Produce
43
from Ceramic Powder
CHAPTER 3
METHODOLOGY
3.1
Research Design
44
3.2
Design of Test Specimen
46
3.2.1
Design of experiment
47
3.2.2
Design of Test Specimen Via
47
SolidWorks
3.3
Raw Material
49
3.4
3D Pinter
54
3.4.1
56
3.5
Processing
Mechanical Testing
58
3.5.1
58
Compression Test as per ASTM D695
3.5.1.1 Equipment/ Testing Apparatus
59
3.5.1.2 Testing Parameter
60
xiii
CHAPTER 4
RESULT AND ANALYSIS
4.1
Stress-strain Relationship of Part Produce from
63
3-D Printer under Compression Force
4.2
Compressive Strength of Part Produce from
68
3-D Printer
4.3
Compressive Modulus of Part Produce from
70
3-D Printer
CHAPTER 5
DISCUSSION
73
CHAPTER 6
CONCLUSION
80
CHAPTER 7
SUGGESSTION AND RECOMMENDATION
81
FOR FUTURE WORKS
REFFERENCES
82
BIBLIOGRAFI
85
APPENDIX
87
1
CHAPTER I
INTRODUCTION
Rapid Prototyping (RP) is a technology that provides the ability to build or
fabricate prototypes for initial design of a product. There are various materials can be
used in producing the prototypes needed, which depends on the RP machine itself. For
3D-Printer Machine, it actually can be simplified as a commercial RP process. Various
process parameters can be found in 3D-printer which affects the character of RP parts;
including build direction, layer thickness, temperature and so on. Layer thickness
actually refers to the thickness of each part being produced by the 3D-Printer Machine.
Before any products become a product that can be use in human life, one sample
or prototype required as a specimen. This is because the sample will used to allow for
demonstration, evaluation or testing for the proposed product. The technology that used
to make the prototype is define as Rapid Prototyping (RP) and usually come first before
a specific mold tool and jigs are design. For make prototyping traditionally required skill
of employee, time and cost. These three causes usually applied for cutting, bending,
shaping and assembly the part that needed.
The procedure was often iterative, with a series of prototypes being built to test
various options. For many applications, this process has been revolutionized by a
relatively recent technology known as layer manufacturing or Solid Freeform
Fabrication(SFF) which is any part from any shape, can be produced in a single process
2
by adding successive layers of material. Usually mold, jigs and die are also include the
quickly fabrication of the tools required for mass production. Now, there are many
different manufacturing process have develop using an increasing the range of material
[1,].
1.1
Rapid Prototyping
Rapid Prototyping (RP) is referred to as a class of technology can automatically
build a physical model from Computer-Aided Design (CAD) data. This technology
make designer quickly create prototypes of their design, although just two dimension
pictures [1, 2, 3, 5, 7, 9,10]. Prototype can also be used in design testing. Other than
that, RP also can be use to make tooling and any production part. RP is usually best
manufacturing process for small production runs and complicated object.
Most
producing prototype take shortly time, but the time that required depends on the size and
the complexity of the object.
This process rather consumes more time make the
prototype but still better than conventional method such as machining. Rapid
prototyping system is a technology that emerges in 1980s. During the modern concept of
Rapid prototyping was conceived and developed; actually the origin of this technology
is back to the 1890s [1]. This is some of the most popular and commonly used RP
technique [3,10]:
i.
Selective laser sintering (SLS)
ii.
Fused Deposition Modeling (FDM)
iii.
Stereolithography (SLA)
iv.
Multi Jet Modeling (MJM)
v.
Laminated Object Manufacturing (LOM)
vi.
Electron Beam Melting (EBM)
vii.
3D Printing (3DP)
viii.
Objet PolyJet Modeling
3
1.2
Three -dimensional Printer
Three-Dimensioning printing refers to a category of rapid technology which is
converting a virtual 3D model to become a physical object. Typically, 3D printer is an
extremely flexible system, capable of creating part of any shape using any material
including ceramics, metals, polymers and composites. 3D printer also generally faster
and easier to use than other additive technologies. Three-dimensional printing (3DP)
developed by the Massachusetts Institute of Technology and licensed to Z Corporation
of Burlington, Massachusetts. The material usually use in this system is limited to two
choices: plaster or starch.
Usually the material that is recommended is the plaster based because it is more
durable and gives better resolution. Starch should be used if need making investment
mold. After finish printing the part, it should be infiltrated. Infiltrants that are used to
wax includes cyanoacrylate (superglue) and Z Max epoxy [4].
A unique capability of three-dimensional printing is the ability to produce
multicolored parts. A part’s color is determined by dyes added to the liquid binder.
Almost any color is possible. Each layer, in essence, is like a full-color image printed on
a flat sheet of paper by an ink-jet printer
Three dimensional printing offers the advantages of speedy fabrication and low
materials cost. In fact, it's probably the fastest of all RP methods. Recently color output
has also become available. However, there are limitations on resolution, surface finish,
part fragility and available materials. The closest competitor to this process is probably
fused deposition modeling [2,10].
4
1.3
Aim of Works
The objective in this project is:
To design and fabricate part from powder- based material using 3D printer.
To investigate the mechanical properties of part produced.
The scope in this project is:
To design a part from powder- based material used in rapid prototyping.
To fabricate part using 3d printer machine.
To investigate the mechanical properties of part including compression test as
per ASTM D695.
1.4
Problem Statement
This research is dedicated to the study of particularly for compression behavior
of part which produces using 3D-Printer Machine. From the literature review, many
researches reported about the specimen dimension, technical specification of machine
but very few resources have reported about mechanical properties of powder-based part
produced from the 3D Printer.
1.5
Planning and Execution
Table 1 below depicts the research activity that is carried out throughout the
project. The first four months is dedicated to the literature review and design of the
experiment
(DOE)
that
cover
the
research
methodology.
5
Table 1.0: Gantt Chart for the Research Activity in this Project.
Research
Activity/Time
W1
W2
W3
W4
W5
W6
PSM 1
Problem Statement
Literature Review
Rapid Prototyping
3D Printer
Raw Material used
Mechanical
Properties
Methodology
Experimental review
Research Design
DOE
RP Process
Mechanical Testing
Design of Test
Specimen
Report Writing
Submission Report
PSM 2
Literature Review
RP/3D Printer
Raw Material
Mechanical
Properties
Methodology
Produce Specimen
Procedure of
Mechanical Testing
Mechanical testing
Compression Test
Result & Findings
Report Writing
Submission report
W7
W8
W9
W10
W11
W12
W13
6
CHAPTER II
LITERATURE REVIEW
2.1
Rapid Prototyping
Rapid Prototyping (RP) refers to a group of technologies that can fabricate
physical, three dimensional part of arbitrary shape directly from Computer Aided Design
(CAD) and Computer Aided Manufacturing (CAM) by fully automated, fast and highly
flexible process [2, 5, 7, 8, 9, 10]. According to the Wohler Report (2004), Rapid
Prototyping refers to fabricate a physical model of a design using digital driven, additive
processes. RP also produce model very quickly from 3D CAD data, CT and MRI scans,
and data from 3D digitizing system. This means, Rapid Prototyping method can save the
processing time and also save cost producing the prototype than using conventional
technique for fabricating physical model which can be more expensive and also time
consuming which may take a few days or even weeks [2, 5].
Rapid Prototyping was emerged in 1980’s, where the high technology was
conceived, developed and promote in 1980’s. 1890’s is the date of the origin technology.
For the early history for rapid prototyping, it’s also known a layered manufacturing.
This is because of the concept for building something using layer by layer at
least two technical areas: topography and photosculpture. In that time, the method used
7
to produce tool or even prototype and usually the product that have produce in small
quantities [2].
This technology allow designer quickly create prototypes of their design,
although just two dimension pictures. Designer will makes the prefect visual aids for
show their ideas to their co-workers and also to customers. Prototype usually numerous
use such as, it can be use in design testing. Other than that, RP also can be use to make
tooling and any production part. RP is usually best manufacturing process for small
production runs and complicated object. Most producing prototype take shortly time,
but the time that required depends on the size and the complexity of the object.
RP system has it own advantages such as; prototype that required can build even
though the prototype has a complex shape. It also builds the prototype without setting
the arrangement of the machine. Besides that, RP also build the prototype using multiple
materials by available technique. Other than that, RP has reduced time to market. Cut
trial cost and improved the quality of the product.
RP have become an important part of the product development process. By using
RP has time taken can be reduced, cut cost and improve the quality of the product. This
means, RP allowed user do and fabricate the design and prototype to verify before they
involve in the expensive tooling and fabrication of mass production. Below are several
type of application in education and industry [2].
i.
Application in Product Development
In this new era of global for providing product and service, RP
technology become one of the medium that make the process become
easier. This is because all the company involve in product development
and manufacturing will face with the competition to bring the product to
market faster, cheaper and also with high quality functioning. In this
problem, RP is the best solution for the problem that help all companies
by reduce the cycle of product development and also during making the
8
design for making improvement of the product. The most application can
be dividing into three major categories:
a) Prototype Design Evaluation
b) Prototype for Function Verification
c) Prototype for Manufacturing Process Validation
ii.
Application in Reverse Engineering
Reverse Engineering is science by taking the physical model and produce
it surface geometry in 3D data file on CAD file. RE is the faster way to
get 3D data into any computer system. The example for this application is
situation includes hand made prototypes, craft work, dental application
and reproduction of old engineering object.
iii.
Application in Casting and Pattern Making
This application is important for casting and pattern making. Casting
allows fabricate complex shape but for the simple shape machining can
be used.
iv.
Application in Rapid Tooling
According to the rapid solution web, Rapid tooling is using a rapid
prototype, either indirectly or directly, as a tooling pattern for creating a
mold. Rapid tooling techniques enable you to have molds with the
correct material at a substantially reduced cost in a fraction of the time it
takes to produce parts from production tooling processes. The greater the
complexity of the part, is the greater the benefits of cost and time.
v.
Application in Medical
Application in medical is one of the most successful applications for
rapid manufacturing. For the example this application is used to the
production of customized hearing aids. This is because every ear is
9
different, and the size of the parts makes it possible to fabricate the
products in large, economical batches with existing equipment.
vi.
Application in Rapid Manufacturing
a. In Rapid manufacturing, there are still having a lot of challenges for the
limitation of speed, material and accuracy. But by using the rapid
prototyping
technology
most
of
the
companies
show
the
successfully[2,3,7,9]
According to Rochus, et.al (2007) their article was reported rapid prototyping
and manufacturing are known to be destructive technologies. Everyday industry used of
this method has increase rapidly. The principal of this technology of manufacturing parts
is layer by layer starting from liquid, paste or powder. After the material is deposited,
the selecting surface is treated according to a process define by the chosen technique in
order to solidify a cross section of the final component. This process are applied for
prototyping, small series, injection moulds manufacturing, mock-ups and also used in
several engineering sectors. In their article also state the general description for the rapid
prototyping technique such as, Stereolithography (SLA), Selective Laser Sintering (SLS)
and Jet Based Technology. The start with a 3D CAD model, then the model need to
convert to the stereolithography (STL) format. Only this format can be read by the
machine. This is because the format will change dividing the model into layer form. By
dividing the object into the layer form, the machine will printed the object layer by layer
according to the STL format. This process is continuously until the layer becomes an
object.
It is reported from in their article, rapid prototyping is a innovative technology
develop rapidly and very useful for industry. The aim of this technology is to produce
prototype relatively quickly. Most the RP system is now commercially available. There
are three type of system that can be classified according to the material used which is
powder based, resin based and sheet based. For powder based, the RP process includes
the Selective Laser Sintering (SLS) and 3D Printing process. Resin based process such
10
as Stereolithography (SLA) and the laminated sheet based process included the
Laminated Object Manufacturing (LOM) process. Generally all the principal of process
are similar but the things that make the technique different are the materials that use to
make prototyping. In this paper also mention the advantage of this technology such a
reducing time and cost. This is because, all the process will make the prototype in the
short time than the traditionally method. And also can produce more prototypes in one
time. Besides that, this technology make the cost reduce by making the prototype in
exactly as the real one. But, this technology has the limitation such as the quality and
accuracy. But not all the system of RP has this problem [Choi,et al (2003)].
According to Durham. (2003) Rapid Prototyping is very useful in industry. This
is because RP is a powerful tool to reducing time to market and it also improving quality
and reducing cost. He also said the challenge is during selecting the suitable process that
need to use. During making decision for what process that need to choose, the important
thing that needs to consider is combination with the intended material. This is because;
selecting a process without considering the material will yield the questionable result. In
his article also state the RP process that usually used in industry which is,
Stereolithography (SLA), Selective Laser Sintering (SLS) and also PolyJet. In this
article also mention comparison the process as the material available for each.
Stereolithography (SLA) process is used material in liquid resin. The process is using
ultraviolet laser to solidify the material. Although the SLA is limited in its range of
applicable material, it is suitable for conceptual visualization. Selective Laser Sintering
(SLS), the material is from powder material. The SLS process create the object by
heating the powder using heat from a carbon dioxide laser fuses (sinter). The advantage
for this process is more widely using in industry and also suitable for function analysis.
Hatsopoulos, (2000) wrote that Rapid Prototyping introduces a method that is
called “3D Printing”. Before this, the model making take too much time and the cost is
high. Also the technique is always limited for use. But it is less expensive and faster
when using 3D printing method. From this, this technology give the designer better
access to model, which is provide the freedom to make many more of model. This