SEARCH RESULT

Molding process is one of the mostly used manufacturing techniques. Conventional molds are generally made in woods. These are mostly produced by CNC machine. Small changes in the design requires remolding. This takes time and costs a lot. Additive manufacturing (AM) may lower the design and optimization costs. This study aims to compare prototyping costs between additive and classical manufacturing techniques for producing mold of Agitator Propeller. The Computer Aided Design (CAD) model were prepared using Autodesk Inventor Software. Then, the model was exported as STL file format for rapid prototyping. Hypercube Evolution desktop type 3D printer with 90-300 microns layer height manufacturing capacity was used to produce the sample. The printer settings were prepared with Cura software. Infill density and layer height of specimen were determined as 20% and 200 microns, respectively. The heated bed temperature was selected as 60°C to increase bonding and surface quality. The produced propellers were used as manufacturing the casting molds. The model development using wood and 3D printing were compared in terms of technical and economical aspects. Dimensional accuracy was measured with a caliper. The cost effectiveness analysis was systematically conducted using Excel. The results from the cost-benefit analysis indicated that using 3D printers lowered the prototyping cost as much as three times.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu İsmail Böğrekçi Neslihan Demir Utku Köse

Küreselleşme emek yoğun üretim modellerinden bilgi/teknoloji yoğun üretim modellerine geçişi hızlandırmıştır. Araştırma - Geliştirme (Ar-Ge) ve Tasarım faaliyetleri, şirket için mikro düzeyde üretkenliği ve karlılığı artırırken, makro düzeyde ihtiyaç duyulan dönüşümün artmasına katkıda bulunmuştur. Ar-Ge ve Tasarım Merkezlerinde ilerleyen ürün ve hizmetler, hem endüstriye hem de ülkemize etkin bir şekilde katkıda bulunmaktadır. Ar-Ge ve Tasarım faaliyetleri belirli disiplinlerle sınırlı olamaz. Üretimde kullanılan sensörlerin, aktüatörlerin, tezgâhların ve ekipmanların dijitalleştirilmesi, Ar-Ge ve Tasarım Merkezlerinde çalışan insanlar tarafından gerçekleştirilebilir. Sanayi 4.0'ın gerçekte ne olduğu ve katkıları hakkında yüksek profilli bir farkındalık çalışmasına ihtiyaç vardır. Sanayi 4 bileşenlerinde çalışan teknoloji şirketleri, danışmanlık firmaları ve akademisyenleri bir araya getirmek, karşılıklı öğrenme ortamları yaratma açısından olumlu olabilmektedir. İşlemler sırasında büyük verilerin toplanması, üretim hakkında daha doğru sonuçlar elde etmemizi sağlarken, üretimi durdurma veya hatalı ürünlerin üretimini önleme gibi durumların ortadan kaldırılmasına da yardımcı olmaktadır. Örneğin, otomobil veya parça tedarik endüstrisindeki kullanıcılar silindir kafasının ölçüm verilerine sahiptir. Çalışma materyali, üretim süreci ve üretim koşulları ile birlikte birçok veriyi depolayabilmektedirler. Bu şekilde, silindir kafasını etkileyen tüm veriler tek bir veri tabanında toplanmaktadır. Böylece, yazılımın ve müşterilerin üretim sistemlerine entegrasyonu gittikçe önem kazanmaktadır. Globalization has accelerated the transition from labor intensive production models to knowledge/ technology intensive production models. Research & Development (R&D) and Design activities increase productivity and profitability for the company at micro level and contributed to the increase in the needed transformation at macro level. Products and services progressed in R&D and Design Centers improve effectively to both the industry and our country. R&D and Design activities cannot be limited to certain disciplines. Digitalization of sensors, actuators, workbenches and instruments used in manufacturing can be achieved by people in design and R&D Centers. There is a need for a high- profile awareness study of what Industry 4 is and its contributions. Bringing together technology companies, firms and academics working in industry 4 components will be positive in terms of creating mutual learning. The collection of big data during the processes allows us to achieve more accurate results about the production helping to avoid the situations like stopping the production or preventing to producing of faulty products. For example, users in the automobile or parts supply industries have the measurement data of the cylinder head. They can store many data together with working material, production process and conditions. All the data affecting the cylinder head is collected in a single database. Therefore, the integration of software and customers into the production systems are becoming increasingly important.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu

The aim of this study is to investigate the effects of contact and the raft on surface roughness of the produced parts with rapid prototyping technique. The Computer Aided Design (CAD) model of the cube samples with the dimensions of 10x10x10 mm were prepared with Autodesk Inventor software. 3D Solid models were exported as STL file format to set in Simplified3D software. The samples were manufactured using Prusa İ3 desktop type 3D printer with 90-300 microns layer height manufacturing capacity. The layer height and the infill density of the specimens were used 200 microns and 50%, respectively. The sample manufacturing conditions were determined as with and without raft. Three samples were produced for each set. The heated bed temperature was selected as 60°C to increase the bonding and surface quality. The extruder temperature was set to 195°C. After the manufacturing process; the roughness of the surfaces (1: directly contact to the print plate, 2: contact to the raft surface 3: non-contact surface) were measured. Surface roughness measurement of the specimens were conducted in micro-scale. The surface investigations were performed with a rotating-Nipkow disc confocal microscope (NanoFocus-µsurf) that has the specifications of 1.6 µm spatial resolution, 0.04 nm Z resolution and 3.1 mm Z range. The measurement results showed that the smoother surfaces could be obtained using raft in configuration (mean value of Ra=5.67 µm).

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu H. Saygın Sucuoğlu İsmail Böğrekçi Aslı Gültekin

The aim of this study is to investigate the effect of the extrusion speed on surface roughness and quality of the produced components with additive manufacturing technique. Computer Aided Design (CAD) model of specimens were prepared using Autodesk Inventor Software. Then the models were exported as STL file format for rapid prototyping. The specimens were produced with the dimensions of 10x10x10 mm. Cube specimens were manufactured using Prusa İ3 desktop type 3D printer with the 90-300 microns layer height manufacturing capacity. The printing settings were prepared with Simplified3D software. Layer heights were used as 200 microns for all samples. The heated bed temperature was selected as 60°C to increase the bonding and surface quality. The extruder temperature was set to 195°C. The samples were produced with the extrusion speeds of 20, 40, and 60 mm/s to determine the surface roughness and quality. Surface roughness of the specimens were measured in micro-scale. The surface investigations were performed with a rotating Nipkow disc confocal microscope (NanoFocus - µsurf) with the specifications of 1.6 µm spatial resolution, 0.04 nm Z resolution and 3.1 mm Z range. According to the obtained results from surface roughness measurements the relationship between extrusion speed and surface roughness of produced samples were analyzed. The results showed that the lower extrusion speed the better surface roughness.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu İsmail Böğrekçi H. Saygın Sucuoğlu Neslihan Demir

The aim of this study is to determine the shape effect on the dimensional accuracy of the manufactured components with additive manufacturing method. For the printing model, some capital letters from A to O were embossed on a rectangular shape plate with extrusion through join, cut to half depth of plate thickness and cut through options using Autodesk Inventor Software. Then the models were exported as STL file format for rapid prototyping. The text sizes were created as 15 mm to obtain better resolution and printing quality. The measurement samples were produced using Prusa İ3 desktop type 3D printer with 90-300 microns layer height manufacturing capacity. The printer settings were prepared with Simplified3D software. Infill density and layer height of specimens were determined as 20% and 200 microns. The heated bed temperature was selected as 60°C to increase the bonding and surface quality. The extruder temperature was set to 195°C. Three embossed specimens with join, cut half and through types were manufactured for the comparison of dimensional accuracy. After producing, the images of the specimens were acquired using 20.2 Megapixels high resolution CCD camera. The obtained images were processed by different image processing techniques such as binarizing and edge detection. Images of three replicated parts emboss with join, cut half and cut through were then correlated with each other to find the dimensional errors. The results showed that embossing with join produced less deteriorated shapes in terms of correlation coefficient results.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu İsmail Böğrekçi H. Saygın Sucuoğlu

The aim of this study is to investigate the effects of the infill type and density on hardness of the manufactured components with rapid prototyping technique. Computer Aided Design (CAD) models of specimens were prepared using Autodesk Inventor Software. Then the models were exported as STL file format for rapid prototyping. Disc shape specimens were produced with the diameter of 20 mm and thickness of 5 mm using Prusa İ3 desktop type 3D printer with 90-300 microns layer height manufacturing capacity. The printer settings were adjusted with Simplified3D software. The infill types were selected as rectilinear (linear), grid (diamond) and honeycomb (hexagonal). Layer heights were used as 200 microns for all of the samples. For each infill types; the specimens were produced with the infill density values of 15, 25, 50, 75 and 100%. The heated bed temperature was selected as 0 60 C to increase the bonding and surface quality. The extruder temperature was set to 195 C. Then the hardness of the manufactured specimens were measured with EMCO-TEST DuraScan micro hardness machine that has ability to perform Vickers and Knoop methods range between 10 gf and 10 kgf. In order to find the effects of the infill type and density on hardness of 3D printed specimens, the obtained results from Vickers micro hardness measurements were compared. The hexagonal infill with the density of 100% showed the highest hardness and also the hardness patterns could be presented from high to low as Hexagonal > Linear > Diamond.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu İsmail Böğrekçi H. Saygın Sucuoğlu Oğulcan Turhanlar

The aim of this study is to investigate the relationship between the fusion temperature and dimensional accuracy of the 3D printed components. The Computer Aided Design (CAD) model of specimens were prepared using Autodesk Inventor Software. Then the models were exported as STL file format for rapid prototyping. Prusa İ3 desktop type 3D printer with 90-300 microns layer height manufacturing capacity was used to produce the samples. The printer settings were prepared with Simplified3D software. Infill density and layer height of specimens were determined as 20% and 200 microns, respectively. The heated bed temperature was selected as 60°C to increase the bonding and surface quality. The specimens were produced as sphere with the diameter of 10 mm. The samples were manufactured with five different extruder temperatures (185, 195, 205, 215, and 220°C) that directly affect the fusing temperature and process. Three samples spheres were produced for each fusion temperature. After the design and manufacturing processes the dimensions of produced samples were measured with image processing techniques. The obtained results were compared with each other to find the relationship between the dimensional accuracy and fusion temperatures. The results showed that the minimum dimensional error was obtained from the fusion temperature of 185°C with the value of 0.290797 mm and percentage of 3%.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Pınar Demircioğlu İsmail Böğrekçi H. Saygın Sucuoğlu Emrah Güven