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High-precision forming method based on prediction of shrinkage error in selective laser sintering combined with milling (本文)

Nguyen, Trung Nghiep 慶應義塾大学

2020.09.21

概要

Selective laser sintering combined with milling (SLSM) is an advanced manufacturing technology that combines selective laser sintering (SLS) and milling in the same workstation. The SLSM technology takes the advantage of both SLS and milling, that is, the ability to fabricate extremely complex and the high precision products. This is a promising technology that allows us to break the limitations of traditional designs based on machining technology. However, shrinkage error is a fundamental problem that significantly affects the accuracy of SLSM. This type of error is caused owing to the shrinkage of the new layers that are deposited on the finishing machined portions in the earlier steps of the forming process. Shrinkage error usually exceeds the expected accuracy of SLSM; therefore, the products of this technology cannot match the accuracy or reach the high precision levels of the designs. Thus, finding a solution for shrinkage errors is extremely important for developing SLSM.

Currently, academic reports on shrinkage errors in SLSM are not available. The mechanism of evolution of shrinkage errors in SLSM is not fully understood. The study of shrinkage errors has many limitations because of lack of equipment and effective methodologies, and valuable time and expenditure for experimenting. Moreover, the SLSM process includes several steps that all can cause shrinkage errors; therefore, determining shrinkage errors at each step is extremely complex.

The final target of this study is finding an effective solution for shrinkage errors in SLSM. To meet this target, the content of this study includes finding an effective methodology to study SLSM shrinkage errors, understanding mechanism of shrinkage errors, finding an effective method to predict shrinkage errors, and finally finding an efficient solution.

This study has successfully built an effective finite element analysis (FEA) model to investigate shrinkage errors in SLSM. The FEA is the main research methodology because of its many advantages such as reduction in time and expenditure, no requirement of special measuring equipment, and the ability to easily determine shrinkage errors at every step of the forming process. The effectiveness of the proposed FEA model is carefully evaluated using experiments. Therefore, the reliability of the study results is strongly confirmed.

Based on the results of the FEA model, the mechanism of shrinkage and evolution of shrinkage errors in the SLSM is fully understood. Three shrinkage rules are proposed to explain the development process of shrinkage error in the SLSM. The three proposed shrinkage rules were evaluated with the experiment results and provided high quality matching effects. Understanding the mechanism of shrinkage errors is important to find solutions for this problem.

Next, a mathematical model is built to efficiently predict the shrinkage error in SLSM. This model is proposed based on the understanding of shrinkage errors presented by the three shrinkage rules. Especially, the parameters of the mathematical model are interpolated using data on shrinkage errors collected from the FEA model. The effectiveness of the proposed mathematical model is confirmed using both FEA simulation and experimental results. Consistent with the FEA model, the mathematical model also provides results that are highly equivalent with the actual results.

Finally, the compensation technique for SLSM is developed using the shrinkage error predictions of the proposed models. The compensation settings for shrinkage errors are calculated based on the results of the FEA and mathematical models. However, the mathematical model has a significant advantage of calculating time. The effectiveness of the compensation technique for SLSM is also evaluated using experiments. With the proposed compensation technique, shrinkage errors can be reduced more than 70% in the confirmed experiments, and the technique is proven to be an efficient solution for shrinkage errors in SLSM.

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