ADVANCE MANUFACTURING (PRODUCT QUALITY)

1. TITLE
ADVANCE MANUFACTURING ( PRODUCT QUALITY )

2. OBJECTIVE
i. ii. To understand machining error To understand the function of Coordinate Measuring Machine and Rapid Prototyping Machine iii. iv. To evaluate the product specimen with the tolerance is (+- 1%) To understand the process of Rapid Prototyping Machine and Coordinate Measuring Machine works.

3. INTRODUCTION Rapid prototype is defined as one of the technologies that used to produce an instant scale model component that generated from 3D CAD software and then convert to CAM and then evaluate by Coordinate Measuring Machine where in industry this technology mostly used in prototype stage which is after the drawing stage.

Drawing

Prototype Pilot Production Mass Production

Quality Assurance

ADVANCE MANUFACTURING (PRODUCT QUALITY)

The advantages of using rapid prototype machine are include to decrease product development time, low material waste, higher energy efficiency and to extend the product life cycle. Nowadays, this machine was applied to some applications such as metal washers, wire forms, sheet metal fabrications, metal stamping and many more.

4. THEORY
This experiment is mainly about the advance manufacturing, advance manufacturing is a new process in order to replace old types of manufacturing process and the advantages of advance manufacturing is its ability to analyse the processed and its failure before it is being made into 3D object. Basically there a few important rules that advance manufacturing takes place, the first thing is about the 3D software.in markets there a many software that use 3D coordinate system to being able to draw object or visualised object into 3D.This will makes the object able to do simulation and the object will be able to reconstructed. This huge advantage of 3D software changes the order of manufacturing industry, in terms of cost of production. This is because the company will be able to use the 3D software to create a new product and being able to do simulation and the failure point of each new product are known before the real product is made. The other advantage of 3D software also is the ability to change its data file to 2D.This ability will enhance the use of software for many purpose for designer, architect and engineer. The example of 3D software that have in market are SolidWork, Solid Edge, Swift 3D and CATIA.

ADVANCE MANUFACTURING (PRODUCT QUALITY)

Example of 3D software:

SolidWork

CATIA

In order to combine all the different working framework for each types of 3D software, a universal file conversion system is created. This is because when using certain types of 3D software and u need to open the file in other 3D software the framework is different. So a universal data file had been created in order to ease the operation. In the industrial of manufacturing the uses of 3D software is closely related to the Computer Aided Manufacturing (CAM), in order to standardise the conversion between 3D software and CAM the .stl (STereoLithography) this file also being called the Standard Tessellation Language. This file has been created by using complex binary codes in order to being able the file to be used in many ways. The consequences of having the 3D software the .stl file comes the new things that has been called the Rapid Prototyping Machine. This machine allow the visualisation of 3D object that having 3 axis system to be printed. This machine work exactly like the paper printer both have ink and mechanism to print onto something. The main difference about Rapid Prototyping is the ability to print and 3D object layer by layer until the object become a solid foundation. The limitation of the Rapid Prototyping is the ability to print a 3D object is limited to only certain material of ink. There are some types of rapid prototyping, the stereolithography also knows as (SLA) the process is mainly about using the laser to turns thin layer of liquid plastic into solid. Meanwhile the other types is the Selective Laser Sintering, this technique is about the laser that will used to turns a powder that will skim the

ADVANCE MANUFACTURING (PRODUCT QUALITY)

powder surface to hardening the surface into desired 3D object that have been created in 3D software. Next is the Fused Deposition Modelling, this technique is same as the technique of printing, the material that flow out of the nozzle layer by layer to produce 3D object. Example of Rapid Prototyping Machines:

3D Printer Cyrus
There are many material that can be used in Rapid Prototyping Machine. Acrylic is one types of the material. This material have properties of plasticity but the different is the amount of elasticity is very low. The ability of this material that can be solidified easily because of it low melting point become a choice to be the material that suitable to be the ink of Rapid Prototyping Machine. The material easily moves through the tiny nozzle and printed

ADVANCE MANUFACTURING (PRODUCT QUALITY)

layer by layer. But in order to form a rigid solid object other material need to support it contained the acrylic so it will solidified firmly. Example of Rapid Prototyping Machine Products:

FDM

SLA

FDM

The use of wax is very suitable because of it behaviour that melt easily and solidified fast. The use of the wax will help the acrylic to hold the position of the shape until the acrylic is fully solidified. By using wax the object or product will form a rigid surface also have a better surface finish. The advantages of using wax also is the ability to removes it from the surface of product. By heating the wax in the furnace the wax is easily removes because the melting point is low, so it will not affected the acrylic because acrylic have higher melting point. After finishing a product the product quality is important rule that have be determined. Product quality can be categorized into certain aspect, the performance, features, reliability, and durability and aesthetics value. All this characteristics is important because the end user of product will evaluate the product quality of the finishing goods. In order to have a good product the tolerance also become a role in functionality of the product. A good tolerance determination will cause the product have a long life durability and maintained the function. Tolerance is very important and necessarily in moving part and temperature variable part.

ADVANCE MANUFACTURING (PRODUCT QUALITY)

Beside the tolerances the calibration also is needed in order to daily or monthly or depends on the use of the product. Calibration will allow the use of the product to precisely accurate and almost zero calibration error. Example of things that calibration in necessarily is product that involves measurement. Lastly, in certain product the roundness of it surface or its physical is needed. Roundness of an object is the calculation of the diameter sides to almost perfectly having less or almost zero difference. Things that required roundness of it playing role is such as the axial of and object, mechanical arm or in car parts.

ADVANCE MANUFACTURING (PRODUCT QUALITY)

5. APPARATUS AND INDUSTRIAL APPARATUS 5.1 APPARATUS

Computer

3D Software

ADVANCE MANUFACTURING (PRODUCT QUALITY)

Coordinate Measuring Machine

Rapid Prototyping Machine

ADVANCE MANUFACTURING (PRODUCT QUALITY)

Specimen Oven

Refrigerator

ADVANCE MANUFACTURING (PRODUCT QUALITY)

5.2 INDUSTRIAL APPARATUS

RAPID PROTYPING MACHINE 1. ProX 950 Manufacturer: 3D System Corporation

Specification: Material Support Work Space Weight Data file Accuracy ProX 950 Accura: Xtreme, CeraMax Composite, Peak, CAstPro, ClearVue, Xtreme White 200, 25 126 x 220 x 228 cm 150kg .stl, .slc +/-0.05mm

ADVANCE MANUFACTURING (PRODUCT QUALITY)

2. MDX-540 Manufacturer: Roland

Specification: Material Support Work Space Weight Data file Accuracy ProX 540 Plastic, resin, wood and non-ferrous metals 500mm x 400mm x 155mm 102kg SRP Player, 3D Engrave, Dr.Engrave +/- 0.05mm

ADVANCE MANUFACTURING (PRODUCT QUALITY)

CENTER MEASURING MACHINE 1. CENTER MAX Manufacturer: Carl Zeis

Specification: Sensor Accuracy CENTER MAX VAST(Variable Accuracy and Speed Probing Technology) 1.6 + L/3000 m (L=Measured length)

ADVANCE MANUFACTURING (PRODUCT QUALITY)

2. DURAMAX Manufacturer: Carl Zeis

Specification: Sensor Accuracy DURAMAX VAST(Variable Accuracy and Speed Probing Technology) XXT 2.4 + L/ 00 m (L=Measured length)

ADVANCE MANUFACTURING (PRODUCT QUALITY)

3D RAPID PROTOTYPING MACHINE ProX 950

ADVANTAGE

LIMITATION

Ultimate Accuracy Better surface finish Support .stl , .slc file

Required special material High cost of material

MDX-540

CENTER MEASURING MACHINE CENTER MAX

Many material supported Very quick for large prototype product Cheap material can be used ADVANTAGE Economic Accurate Ergonomics Easy interface Use VAST Small Use VAST XXT version Calculation computerized

Low surface finish Required special software

LIMITATION 1.6 + L/3000 m (L=Measured length)

DURAMAX

2.4 + L/ 00 m (L=Measured length)

ADVANCE MANUFACTURING (PRODUCT QUALITY)

6. PROCEDURE
1. The specimen was drawn into two different shapes at its centre by a 3D software called Catia Software with the parameters as shown.

20mm

20mm

2. Fonts was crafted on the drawing by these steps in the Catia, Start mechanical design drafting text ( choose font and size ) save as ig2 3. The CAD data was saved in a thumb drive and then been transferred to the computer that connected to the rapid prototype machine. 4. The drawing was confirmed its position to be printed while waiting for the material which are the wax that coated the acrylic in the printer was checked. 5. A work tray was inserted into the slot in the machine where the specimen will be drawn on it. 6. The drawing was printed into scale model component for 1 hour and 52 minutes. 7. After the printing was finished, the specimen was kept in the refrigerator for 10 minutes in order to dry the wax that coated the acrylic plastic to ease the removal of the wax from the acrylic. 8. The specimen was transferred into an oven provided for 15 minutes at 95C to melt the wax which are the melting point of the wax is lower than the acrylic. 9. The specimen was then immersed in hot water in order to remove the wax from the specimen. 10. Finally, it was cleaned by tissue provided for finishing of surface stage of the specimen.

ADVANCE MANUFACTURING (PRODUCT QUALITY)

DATA TABULATION
L3 L3

L4 L1 29 ( 1a )

L2

L4 L1 29 ( 1b )

L2

SPECIMEN 29 ( 1a )
THEORETICAL VALUE (mm) EXPERIMENTAL VALUE (mm) ERROR (%)

SPECIMEN 29 ( 1b )
THEORETICAL VALUE (mm) EXPERIMENTAL VALUE (mm) ERROR (%)

DIAMETER

50

49.568 0.1929

0.864

50

49.702 0.1614

0.596

ROUNDNESS

L1 (5)

20 20

19.741 19.769

1.295 1.155

20 20

19.803 19.761

0.985 1.195

L2 (6)

L3 (7)

20 20

19.552 19.764

2.240 1.180

20 20

19.810 19.735

0.950 1.325

L4 (8)

Table 1 : Table of percentage errors for each specimen

ADVANCE MANUFACTURING (PRODUCT QUALITY)

Graph of Percentage Error of Specimens

2.5

Percentage error

1.5

0.5

0 1 2 3 4

Length of each side

Specimen 29 ( 1a ) Specimen 29 ( 1b )

Graph 1 : Graph of percentage of errors vs. length

ADVANCE MANUFACTURING (PRODUCT QUALITY)

L2

SPECIMEN 29 ( 2b )
THEORETICAL VALUE EXPERIMENTAL VALUE ERROR (%)

SPECIMEN 29 ( 2a )
THEORETICAL VALUE EXPERIMENTAL VALUE ERROR (%)

DIAMETER (mm) ROUNDNESS

50.000

49.651

0.698

50.000

49.545

0.910

0.152

0.0086

L1 (mm) L2 (mm) L3 (mm) a (deg) b (deg) c (deg)

20.000 20.000 20.000 60.000 60.000 60.000

19.509 19.613 20.000 59.300 58.590 61.290

2.455 1.935 0.000 1.167 2.350 2.150

20.000 20.000 20.000 60.000 60.000 60.000

19.752 19.819 19.786 60.100 59.490 60.000

1.240 0.905 1.070 -0.167 0.850 0.000

Table 2 : Table of percentage errors for specimen triangle-shape centre

ADVANCE MANUFACTURING (PRODUCT QUALITY)

ADVANCE MANUFACTURING (PRODUCT QUALITY)

RESULT ANALYSIS
Percentage Error of Diameter (Theoretical Value Experimental Value / Theoretical Value ) x 100 Specimen 29 ( 1a ) = (50 49.568 / 50 ) x 100 = 0.864 % Specimen29 ( 1b ) = (50 49.702 / 50 ) x 100 = 0.596 %

Percentage error of each length (Theoretical Value Experimental Value / Theoretical Value ) x 100 Example : Percentage error of L1 = ( 20 -19.741 / 20 ) x 100 = 1.295 %

Percentage error of angle (Theoretical Value Experimental Value / Theoretical Value ) x 100 Example : Percentage error of angle (a) = ( 60 - 59.300 / 60 ) x 100 = 1.167%

ADVANCE MANUFACTURING (PRODUCT QUALITY)

DISCUSSION
Based on the measurement that have done, it shown that there were errors happened while doing the experiment. In this experiment, there was two different shapes at the centre of the circle. One of it is square and another one is triangle. The value of each error for the square-shape centre was tabulated in Table 1. From the table shown, the comparison is between specimen 29 ( 1a ) with specimen 29 ( 1b ). The highest error happened on the specimen 1a is on length named L3 with the value of percentage of error is 2.240% while the lowest value is on the L2. On the other hand, specimen 1b have the highest error is on the L4 with the value, 1.325% while the lowest one is on the L3 with the value, 0.950%. These results was then visualised in the graph 1. From the graph, it can be seen that specimen 1a gives higher percentage of errors for L1 and L3 compare to specimen 1b. Even though at the L2 and L4 it was recorded that specimen 1b was higher than specimen 1a but it gave a small difference of value. For the triangle-shape centre, the result was tabulated in Table 2 and visualised in Graph 2. From the table, it shown that for the specimen the highest value of percentage error of length is on the L1 with the value, 2.455%. Meanwhile, the highest value of percentage error for angle is on angle c with the value, 61.290 which exceed the theoretical value. These errors was happened due to a few reasons. The first reason is due to machining error. Machining error including the inferior dimensional accuracy. Besides that, error in machining involved on the change in magnitude especially for the triangle-shape centre. It will affect the angle of the triangle. Other than that, to build a part for different orientation it needs a number of layers required or the material shrinkage problem during prototyping that lead to the roundness happened. Thus, from there error would occur. These kind of errors usually happened in rapid prototype machine. In CMM machine, there was some errors that occurred too. One of it is the tool tip of the machine is dominated by the motion error or also called as 21 parametric errors. Due to that problem, reading taken were inaccurate. How the person in charge control the remote also can affect the reading because error appeared.

ADVANCE MANUFACTURING (PRODUCT QUALITY)

CONCLUSION It can be conclude that in this kind of machine or technology also needs accuracy. Technology on prototyping is by using Rapid Prototyping Machine or some sort like 3D Printer and the way to achieve the accuracy is by measure those dimension by using the appropriate machine such as Coordinate Measuring Machine with the correct method or process of using it. These two machine somehow relate to each other to meet accuracy. The tolerance of 1% for the specimens almost achieved except for one to two reading only for each specimen. There was one side of one specimen that meet the tolerance with 0%. Thus, objective was achieved. RECOMMENDATION I. It is recommended that