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2.0 OBJECTIVE
i.
ii.
iii.
prototyping machine
to investigate the percentage of machining error
to identify the parameter of the product specimen that being produce by different
iv.
machine
to analyses the better process in producing a product
3.0 INTRODUCTION
RAPID PROTOTYPING
Rapid prototyping is a process that being used to fabricate a model of an assembly by three
dimensional computer aided design (CAD) data. Rapid prototyping is a process that uses to
fabricate a product using three dimension computer aided design (CAD) data. The first step
in this process is to draw a 3D model by using CATIA and the drawing being saved in stl
(standard translation language) format. The shape of the drawing that being draw is as
follow.
After the drawing being save in the stl file, the error of the file could be checked by using
magic software and any error can be check by the software before submit the file to the rapid
prototyping machine. Then the specimen was put in the freezer to shorten the time taken by
the specimen to harden. Then the specimen were put in the oven to remove the wax that
over the specimen and only leave the acrylic plastic. For the finishing process the specimen
were immerse in the warm water to produce the final product. The specimen that has been
produce were evaluated with the other product that being produce by using other process.
Standard tessellation language or known as stl format file is the file that store three
dimension object data. The purpose of this type of file format is for the moving object through
different software and for 3D printing and computer aided manufacturing. It only described
the surface geometry of the product without any other detail as colour texture or other
common CAD attribute. This type of file was created in order to make it easier for the human
work because this type of data can be read by much software because the 3 dimension
object needs to be move through different software for certain purposes. As example for the
purpose of 3D printing as known the 3D object that being drawn by the CAD software was in
the different format so that stl format file was created to standardize between the different
software.
4.0
APPARATUS
Oven
Glove
Paper
CATIA software
Magics
Scraper tool
Tray
Controllers
Plaster
Work piece
Flatness table
Pointer
4.1
INDUSTRIAL APPARATUS
5.0
EXPERIMENTAL PROCEDURE
6.0
Roundness,
Diameter
Percentag
Average of
Percentage
machine
(mm)
circle, (mm)
e error of
length of
error of length
diameter
specimen,
of specimen,
circle, (%)
1.360
(mm)
49.561
(%)
0.878
Rapid
0.0202
29.592
Prototyping
CNC Milling
Laser
0.0911
0.0124
27.946
29.977
6.8467
0.0767
50.008
49.872
0.016
0.256
Cutting
EDM Wire
0.0195
29.941
0.1967
50.060
0.120
Cut
Percentage error
Rapid Prototyping
CNC Milling
Laser Cutting
EDM Wire Cut
Sample Calculation:
Percentage error =
|T h eoryTExperimental
| 100
h eory
3029.592
100
30
= 1.36%
2. Average of length of specimen.
Rapid prototyping =
49.491+49.551+ 49.624+49.570
4
= 49.561mm
3. Percentage error of length of specimen.
Rapid prototyping =
5049.561
100
50
= 0.878%
7.0
DISCUSION OF RESULT
Rapid prototyping is one of the manufacturing process to create a product design in desired
shape by printing it layer by layer and helps in conceptualization of a design. The difference
with another manufacturing process, the other manufacturing process such as CNC milling,
laser cutting or EDM wire cutting they fabricate the product by subtractive which the form is
shaped by removal material meanwhile for rapid prototyping was vice verse. Below is the
flow chart of rapid prototyping process;
For CMM machine, it one of the computerize device in manufacturing field. The purposes of
CMM machine were to obtain geometry features and object dimension. They precisely
record the dimension in three axis X, Y, and Z. The readings were accumulate by regression
algorithm for the construction. Below is the process of coordinate measuring machine;
For this laboratory, after having rapid prototyping process, we make inspection for the
product by using co-ordinate measuring machine and compare with another manufacturing
process such as computer numerical milling, laser cutting and EDM wire cutting in term of
accuracy in dimension. Regard to the data obtain, rapid prototyping process have the higher
percentage error with 0.878 % compare to others. The most accurate was CNC milling with
0.016 %. For EDM wire cutting, the percentage error was 0.120 % and this was followed by
laser cutting which is 0.256 %. This percentage error was accumulating by make comparism
with CAD drawing in CATIA.
There are a lot of reasons due to the differences of percentage error and one of it was the
process of machining itself. Each process release difference heat when in operation and
cause the product or work piece to bending and when we make inspection with co-ordinate
measuring machine, the result were not accurate. So here we can say that the heat
consume by the work piece effect the percentage error in each process. Moreover, material
uses in each manufacturing process also affect the result where the higher the melting point
of the work piece, the more accurate the result.
For this experiment, we using fully machine, so the only possible error to occur was
accidental errors. They may be due to estimation of values in smallest graduations on the
instruments or due to inexperience in using machine and procedures, certain type of human
errors, errors resulting from variation in definition, the effect from environmental variations
and errors due to insufficient definition of the measuring system.
Some applications of rapid prototyping machine are for making plastic mold part, casting,
master model, and biomedical tool.
8.0 CONCLUSION
In a nutshell, the objective has been successfully achieved since us able to understand
the working principle of rapid prototyping and coordinate measuring machine. We also can
investigate the percentage of machining error by rapid prototyping and coordinate measuring
machine. By using coordinate measuring machine, we able to identify the parameter of the
product specimen that being produce by different machine which are rapid prototyping
machine, CNC milling machine, laser cutting machine and EDM wire cut machine. The better
process in producing a product is CNC milling machine because the average of length
specimen for CNC milling slightly difference between the actual measurements. The value of
CNC milling is 50.008mm. It look more precise compared other machines. The machine that
had lower value of percentage error of length specimen is CNC milling machine namely
0.016%. The product has a hole that circular shape. It means every machine must do a hole
on the product. The diameter circle of laser cutting machine is 29.977mm. It showed the
laser cutting machine is a better machine to produce circular shape because the value of
diameter circles for laser cutting slightly different with the actual measurement. The lower
value of roundness can influence the percentage error of diameter circle. It can give more
accurate measurement of circular shape of the product.
9.0
RECOMMENDATION
1. Make sure the design from the CATIA is pass through Magic Software before
proceed to next stages in order to prevent any surface error of the prototype.
2. Prototype should not be remove from the oven until the wax surface and acrylic
plastic can be clearly distinguished.
3. Clear surface of acrylic plastic can be seen if the prototype is put enough time, so
that there are no remaining white colours of wax on the surface of acrylic plastic.
4. The prototype should be handle with care to avoid any crack or defects to prototype.
5. Standardize the work piece material for each manufacturing process
10.0
Pham,
REFERENCES
D.
T.,
&
Gault,
R.
S.
(1998).
comparison
of
rapid
prototyping
Chua, C. K., Leong, K. F., & Lim, C. C. S. (2010). Rapid prototyping: principles and
applications. World Scientific.Kunzmann, H., Trapet, E., & Wldele, F. (1990).
A uniform concept for calibration, acceptance test, and periodic inspection of coordinate
measuring machines using reference objects. CIRP Annals-Manufacturing Technology,39(1),
561-564.
National Measurement Institute, (n.d.), Coordinate Measuring Machine, Retview on 9
November
2013
at
http://www.measurement.gov.au/Services/Training/Pages/CoordinateMeasuringMachines.as
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