VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Metallien 3D-tulostus Prof. Veli Kujanpää Hitsaustekniikka 17 päivät 6.-7.2017 Savonlinna
Käyttökohteet Prototyyppien teko (Rapid Prototyping) Kehityksen lähtökohta Ensimmäinen kaupallinen laite 1987 Tuotekehityksen nopeuttajana ja tukena Työvälineiden teko (Rapid Tooling) Kiinnittimet Muotit Pistimet, tyynyt Lopputuotteiden valmistaminen (Rapid Manufacturing) Nopeimmin kasvava sektori Wohlers Report 2016 04/05/2017 2
Markkinoista 04/05/2017 3
AM:n ominaispiirteitä EDUT Ei Design for Manufacturing vaan Manufacturing for Design Kevyemmät rakenteet Parempi suorituskyky Paikallinen valmistus Kustomoidut tuotteet ja lyhyet sarjat Monimutkaiset rakenteet mahdollisia Helpompi markkinoille tulo Vähemmän jätettä Yksinkertaisempi arvoverkko Varaosat HAASTEET Laitteet ja materiaalit vielä melko kalliita Valmistus melko hidasta; eli kilpailukykyinen, jos voidaan tehdä muilla menetelmillä Soveltaminen täytyy tuoda lisäarvoa (parantunut käyttö, kustomointi, läpimenoaika, jne. 04/05/2017 4
Topologinen optimointi Mallinnusavusteinen topologinen optimointi on prosessi materiaalin optimaalisen jakauman löytämiseksi annettujen reunaehtojen puitteissa 04/05/2017 5
85% reduction in mass Optimized Design Geometry 04/05/2017 6
Haasteita ja trendejä 1/3 Materiaalivalikoima ja materiaalien hinta Tilanne paranemassa, kun uusia tarjoajia tulee markkinoille Materiaalin kulutus pienempää kuin normaalimenetelmiä käytettäessä Laitteiden hinta Teollisuuskoneissa hinta ei ole vielä varsinkaan metallipuolella laskussa Kysyntä on kova Kehityspanokset edelleen suuret Ominaisuudet paranevat Isot toimijat tulossa markkinoille HP Laadunvalvonta ja toistettavuus Standardit Sensorit Simulointi 04/05/2017 7
Haasteita ja trendejä 2/3 Tuotteiden suunnittelu ja optimointi CAD-ohjelmat hyödyntämään AM:n mahdollisuuksia Suunnittelijoiden koulutus Tarkkuus ja pinnanlaatu Nopeus Nyt metallikappaleissa jälkityöstö useimmiten tarpeen ainakin osittain Voidaan vaikuttaa valmistusparametreillä Tilanne paranee jatkuvasti Muovipuolella uusia tekniikoita kehitteillä Tehokkaammat laserit Usean laserin käyttö Kappalekoot Toisaalta pienempää ja tarkempaa, toisaalta isompaa 04/05/2017 8
Haasteita ja trendejä 3/3 Yksittäiskappaletuotannosta massatuotantoon? 3D Systems Moduloitu älykännykkä Google s Project Ara Race track architecture GE:n uusi 50 miljoonan dollarin tehdas Suuttimia uuteen suihkumoottoriin Tuotantotavoite 40.000 suutinta vuodessa Tuotannon automatisointi Jälkikäsittelyt Tuotantolinjat Hybridikoneet Älyä tuotteisiin Source of picture: Aalto 04/05/2017 9
AM-menetelmät Powder Bed Fusion/(jauhepetimenetelmä) Directed Energy Deposition/(suorakerrostus) Material Jetting/(materiaaliruiskutus) Binder Jetting/(sideaineruiskutus) Material Extrusion/(materiaalin pursotus) Vat Polymerisation/(nesteen polymerisointi) Sheet lamination/(laminointi) 04/05/2017 10
Jauhepetimenetelmä 04/05/2017 11
Jauhepetimenetelmä 04/05/2017 12
Powder Bed Fusion SLM Solutions, EOS, Concept Laser, Arcam Sisma, Trumpf Laser, Orlas, Additive Industries Process monitoring SLM 280 HL 2.0 04/05/2017 13
Suorakerrostusmenetelmä 04/05/2017 14
Directed Energy Deposition Optomec, Beam, Insstek, Trumpf, OR Laser, Sciaky, 04/05/2017 15
Hybrid manufacturing DMG Mori, Hermle, Matsuura, Optomec, Beam, Fanuc, Mazak, Sodic 04/05/2017 16
Standardin mukainen nimi: Lisäävä valmistus (Additive Manufacturing, AM) 3D-tulostus (3D printing) Muita nimityksiä: Additive Laser manufacturing, ALM Standardin mukainen nimi: Jauhepetimenetelmä (Powder Bed Fusion), PBF Muita: Selective laser sintering, SLS Selective laser melting, SLM Direct metal laser sintering, DMLS Direct metal laser melting, DMLM Direct laser sintering, DLS Standardin mukainen nimi: Directed Energy deposition DED Muita: Laser Metal Deposition, LMD Direct Laser Deposition, DLD Direct metal tooling, DMT Wire-arc addive manufacturing, WAAM 04/05/2017 17
Comparison of AM methods Characteristics Directed Energy Deposition Powder Bed Fusion Materials diversity large Limited (expand rapidly) Part dimensions No limitation Limited by process chamber Part complexity limited Almost unlimited Min. wall thickness 1 mm 0.1 mm Deposition rate 500 cm 3 /h 100 cm 3 /h Layer thickness 0.5 mm 0.015 0.1 mm 04/05/2017 18
Powder Bed Fusion and Directed Energy Deposition Process phases Design Material handling AM part manufacturing Post processing Quality control Part orientation and print layout Design of support structures Selecting the process parameters Specifying the required postprocessing steps POWDER HANDLING Procurement/production of metal powder Sieving Drying Filling the powder container Powder removal Powder Bed Fusion Removal of build platform from the machine Stress relief Detaching parts from build platform and removal of support structure HIPing Heat treatments Dimensional properties Surface quality Geometrical properties Mechanical properties Material properties Optimization Capability of machines Simulations (e.g. thermal behavior) Design for AM Fixturing of post processing Powder disposal Directed Energy Deposition Machining Sand- and shot peening Drum- and hand grinding Polishing Other finishing 04/05/2017 processes 19 Coating
VTT Approach from raw materials to component performance, and vice versa Experimental route Hot isostatic pressing (HIP) Raw materials Other posttreatments Gas atomization treatments 3D printing Component testing Performance Processing Structure Properties Modelling digital route AM design, optimization 04/05/2017 20
Case: Better performance - hydraulic valve block 21
22 Initial Design of Nurmi Cylinders Oy Traditional Valve Straight and circular drillings Auxiliary drillings that need to be plugged afterwards Risk of leakage Initial weight: 2,5kg VTT Technical Research Center of Finland investigated what would be the ideal configuration for the part of their customer Nurmi Cylinders Oy 04/05/2017 22
23 Iterative design workflow Meshing Hypermesh Optimization Optistruct 1st Simulation Optistruct Approved Remeshing Surface data 3-matic STL Analysis Hyperworks Due to the redesign tools, the maximal stress regions were solved 04/05/2017 23
3D printed optimized hydraulic valve block Critical component of hydraulic cylinder (offshore) Small series, customized products Optimized mass: 489 g (compared to original mass 1.446 kg) 66% reduction Lower footprint No drilling => no pluging => no leaking! Better fluid flow due to optimized fluid channels 04/05/2017 24
Case: Effective tooling tool insert 25
Injection molding tool - A case product, a cone-shaped thermoplastic elastomer grommet 04/05/2017 26
Current design: many parts 04/05/2017 27
Injection molding tool - Cooling performance of an injection molding tool has an essential meaning in its production efficiency - In this case 3D printed tool core components have been designed and manufactured incorporating conformal cooling channels - Printed by selective laser melting, allowing design freedom for such implementation. - By conformal cooling, a significant improvement has been achieved in reducing cycle time of the injection molding process of the selected product. 04/05/2017 28
Injection molding tool - Several conformal cooled tool core components were designed - The rightmost geometry represents conventional cooling channel - Main dimensions 45 x ~97 mm, material tool steel1.2344 04/05/2017 29
Injection molding tool - After 3D printing, necessary heat treatments were applied for the cores. - The tools were machined - Hardness 54 HRC (after heat treatment) 04/05/2017 30
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- Performance evaluations were made by infrared scanning of the cores separately, and finally in connection of the injection molding tool and trial runs with it. - The picture represents an example of thermal imaging of a core. It reveals that tip area of the core cools down rapidly as a consequence of the conformal cooling channels inside. 04/05/2017 32
- Responsiveness of the cores was remarkably fast when making tool temperature change - => processing window of the production is much larger - In comparison with conventionally manufactured tooling solution, cycle time reduction has been significant. - The cycle time was cut by 50%, approximately. 04/05/2017 33
Case: tool insert for cabling grommet mold Tool insert SLM manufactured at VTT H13 Tool Steel (1.2344) Hardness (after heat treatment) 54 HRC Ra as build 3-7.1, after machining ~0.8 Successful trial Thermoplastic elastomer (TPE) 34
Case: Post-processing automation turbine blade 35
Case study: turbine blade handling Based on real customer need Need: automation of handling of casting channels or support structures Possibility to add more automatic postmachining Because of security the original blade structure is not presented, but a public domain structure is used. The principle is similar as the real case. 36
Case study, con. AM components 1. Robot gripper inserts 1. Form of blade geometry 2. Heat-resisting, not metals Printed of ULTEM polymer 2. Positioning stand for the blade 1. Form of blade geometry 2. Not metal. Printed of ULTEM polymer 3. Turbine blade 1. Made by AM on inconel. Made for demonstration. The real blade is another super alloy 2. Inside cooling channel, difficult to made by conventional methods 3. To be made 2 pieces. Another one is left to have the supporting structure for later studies on automation 1 2 3 37
Case study: research topics 1. Robot gripper inserts 1. Heat-resisting material 2. Maximizing friction => minimizing the press force 2. Positioning stand for the blade 1. Economic manufacturing of blades 3. Turbine blade 1. Accuracy 2. Optimation of surface roughness => minizing the machining work 3. Minimizing the support structures Demo will be shown in Materials Performance Days, Tampere 8.-10.6.2015 38
SLM process optimization for H13 04/05/2017 39
Scanning speed (mm/s) Scanning speed (mm/s) Hatch width (µm) Hatch width (µm) SLM process optimization for H13 Creating the experimental designs Using D-optimal design of experiments 150 140 130 120 110 100 VED 50 VED 100 90 400 600 800 1000 1200 1200 1000 800 600 Scanning speed (mm/s) VED 50 VED 100 Printing samples and measuring density using image analysis Fitting a numerical model and calaculating the optimal parameters Scanning speed (mm/s) 400 100 150 200 250 300 Power (W) Power (W) 04/05/2017 40
Density and mechanical properties Parameters by machine supplier Density = 99,80 % Optimized parameters Density = 99,94 % 04/05/2017 41
Stress (MPa) Stress (MPa) 2000 1800 1600 1400 1200 1000 800 600 400 200 0 Mechanical properties - Original vs. Optimized Heat treatment Procedure Hardness Stress relief anneal Hardening and tempering Conventionally manufactured (Reference) Yield strength (Horizontal) As built Initial Optimized Reference Stress relief annealed Hardened and tempered Held at 650 C for 2h Held at 1030 C for 30min + quench in oil Tempered at 400 C for 2+2h Held at 1025 C for 30min + quench in air Tempered at 550 C for 2+2h Conventionally manufactured 2000 1800 1600 1400 1200 1000 800 600 400 200 0 Ultimate tensile strength (Horizontal) As built Initial Optimized Reference Stress relief annealed Hardened and tempered 45 HRC 55 HRC 52 HRC Conventionally manufactured 04/05/2017 42
Services 04/05/2017 43
Services R&D partner from feasibility review up to total revolution Technology and market surveys Foresight & business landscape Networks and value chains Co-creation with right partners Ideas and feasibility studies Creativity workshops combined with engineering reality Piloting and verification Proof-of-concepts in real life field tests Improving current products and trouble shooting Analyzing & identification of opportunities & problems Visualization of phenomena via modeling Solutions via tailoring materials & production process Design of materials and manufacturing Harder, stronger, more economical, more ecological New and improved manufacturing processes Market potential and technical feasibility Conceptual design Development phase Piloting and verification Production development Mass production 44
Other examples 45
Other VTT 3D printed examples Digital spare part 3D printed mareging steel critical spare part (SLM) Housing for fan 3D printed housing for fan, difficult to manufacture conventionally (FDM) Nanocellulose scaffolds Demonstration of nanocellulose based scaffolds (DWP) Optical instrument housing Production of series of one (PIJ UV) Chocolate Customized wobblers Energy harvesting tree Biocomposite branch Customized chocolate (DWP) 3D printed lures for fishing Prototype of 3D printed artificial Artificial branch 3D printed from 04/05/2017 entusiastics (FDM) tree for energy harvesting (FDM) experimental biocomposite (FDM) 46
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