3D Printing of Functional Parts and Their Structural Integrity
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ME519 MEng Group Project 3D Printing of Functional Parts and their Structural Integrity Final Report Group Q Andrew Gilmour Muhammad Fazril Abdul Latif Martin Gutierrez Benito Giovanni Ressurreição Piffer Supervisor: Dr. Tugrul Comlekci Website: http://strath3dprinting.wix.com/strath3dprinting March 2016 3D Printing of Functional Parts and their Structural Integrity ME519 Contents Acknowledgements .................................................................................................... iii Definitions ................................................................................................................... iv List of Figures .............................................................................................................. v Executive Summary ................................................................................................... vii 1. Background .......................................................................................................... 1 2. Scope .................................................................................................................... 2 3. Project Management............................................................................................. 4 3.1 Project Management Requirements ............................................................... 4 3.2 Group Structure and Management ................................................................ 4 3.3 Project Timeline ............................................................................................ 9 3.4 Budget and Cost Management .................................................................... 10 3.5 Risk Management ........................................................................................ 12 3.6 Communication ........................................................................................... 15 3.7 Document Control ....................................................................................... 17 3.8 Workshop Arrangements ............................................................................. 17 4. Additive Layer Manufacturing ........................................................................... 19 4.1 Overview ..................................................................................................... 19 4.2 ALM Technologies ...................................................................................... 19 4.3 The RepRap Project ..................................................................................... 21 5. Printer Selection and Assembly ......................................................................... 22 5.1 Printer Selection .......................................................................................... 22 5.2 Assembly ..................................................................................................... 23 5.3 Printer Features ............................................................................................ 24 6. Printing Process .................................................................................................. 29 6.1 Overview ..................................................................................................... 29 6.2 Calibration ................................................................................................... 29 6.3 Print Surface Adhesion ................................................................................ 31 6.4 Model ........................................................................................................... 32 6.5 Slicing .......................................................................................................... 34 7. Testing ................................................................................................................ 40 7.1 Purpose ........................................................................................................ 40 7.2 Experimental Work ..................................................................................... 41 7.3 Production of Samples ................................................................................. 42 i 3D Printing of Functional Parts and their Structural Integrity ME519 7.4 Tensile Testing ............................................................................................ 49 7.5 Results and Discussions .............................................................................. 51 7.6 Conclusions ................................................................................................. 62 7.7 Future Work ................................................................................................ 63 8. Microscopy ......................................................................................................... 64 8.1 Objectives .................................................................................................... 64 8.2 Execution ..................................................................................................... 65 8.3 Observations ................................................................................................ 73 8.4 Conclusions ................................................................................................. 77 8.5 Future Work ................................................................................................ 77 9. Component Design and Printing ........................................................................ 78 9.1 Challenges ................................................................................................... 78 9.2 Plotting Aerofoil Profiles ............................................................................ 79 9.3 Design Concepts .......................................................................................... 81 9.4 Printing ........................................................................................................ 83 9.5 Conclusions ................................................................................................. 91 10. Analysis of 3D Printed Components .................................................................. 93 10.1 Problems with Analysis ............................................................................... 93 10.2 Conclusions ................................................................................................. 95 11. Project Conclusions ............................................................................................ 96 12. Future Work ....................................................................................................... 97 12.1 Printer Expansions and Upgrades ................................................................ 97 12.2 Testing of Printed Structures ....................................................................... 99 13. Reflection on Group Performance ................................................................... 100 13.1 Achievement of Project Objectives ........................................................... 100 13.2 Group Structure ......................................................................................... 101 13.3 Communication ......................................................................................... 102 13.4 Overcoming of Challenges ........................................................................ 102 13.5 Time Management ..................................................................................... 103 13.6 Reporting ................................................................................................... 104 14. References ........................................................................................................ 105 Appendix 1: ME519 Project Contract Appendix 2: Test Data ii 3D Printing of Functional Parts and their Structural Integrity ME519 Acknowledgements The group would like to extend a warm thanks to a number of individuals who have provided assistance, guidance and support to the group throughout the duration of the project. The group drew upon the knowledge and expertise of a number of staff members from the Department of Mechanical and Aerospace Engineering at the University of Strathclyde. Firstly, thanks must be extended to Dr. Tugrul Comlekci who, as project supervisor, provided the necessary direction required to support the group throughout the entire project. His guidance and enthusiasm, particularly in the early stages, was crucial to the development of the project objectives and timeline. Thanks must also be extended to the laboratory staff of the department. The group are indebted to a number of individuals who provided the assistance necessary to ensure the project kept moving. Specifically, the group would like to thank Mr. Chris Cameron who showed an enthusiasm towards the project and provided assistance and guidance on a number of issues. Thanks must also be given to Mr. James Gillespie who provided invaluable advice with regards to the use of the tensile testing equipment. The group are also particularly thankful to Mr. Neil McCrindle and Mr. Jim Doherty of the department stores, who worked to meet the group needs at all times without question. Mr. James Kelly from the Metallography Laboratory and Mr. Gerry Johnston from the Advanced Materials Research Laboratory also played key roles in maintaining good progress, providing assistance on running analysis and acquiring images of vital importance in optical and electron