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Additive manufacture of cores for aerospace: Linking quality
and controlDavid Pollard - [email protected] - 20th October 2016
SAMPE UK and Ireland Chapter 2016 Masterclass – Additive Manufacture
The Manufacturing Technology Centre, Ansty Park, Coventry
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Motivation
Source: http://www.3ders.org/articles/20160323-airbus-seeks-to-3d-print-half-of-its-future-airplane-fleet.html
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Motivation
• Aurora Flight Science and Stratasys collaboration
• Demonstrates feasibility of custom aircraft• Reduced cost
• Faster design time
Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciences
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Motivation
• Faster design iterations• 50% Design and Build time
reduction
• 80% AM components
• ULTEM FDM Plastic• Meets FAA Flame, Smoke, and
Toxicity (FST) requirements
Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciences
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Motivation
• Impossible Objects:• Composites Based Additive Manufacture (CBAM)
• Laminate-based method for long-fibre reinforcement printing
• Collaboration with Aurora Flight Sciences• Produced AM stabilisers capable of taking
landing load
Source: http://www.compositesworld.com/articles/3d-printed-composite-parts-provide-solution-for-uav
CompositesWorld: September 2016
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Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Introduction
• Processes• Vat Polymerisation
• Powder Bed Fusion
• Binder Jetting
• Material Jetting
• Sheet Lamination
• Material Extrusion
• Directed Energy Deposition
• ASTM F2792:• “process of joining materials to make
objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”
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Introduction
• Google Trends:• Search terms:
• 3D printing (Industry)
• Manufacturing (Industry)
• 3D printing was more commonly used than Additive Manufacturing
• Results are the percentage of peak searches
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Introduction
3D printing (Industry)
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% o
f p
eak
sear
ches
Introduction
3D printing (Industry)
Manufacturing (Industry)
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% o
f p
eak
sear
ches
Introduction
Bel
ief
Time
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Introduction
Bel
ief
Time
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Introduction
Bel
ief
Time
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Introduction
Bel
ief
Time
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Introduction
Source: European Commission Report:Identifying current and future application areas, existing industrial value chains and missing competences in the EU, in the area of additive manufacturing (3D-printing)
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Introduction
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Ridged print failure - nozzle blockage
Sprue – insufficient retraction to stop flowSupport structures
Peeling from print bed
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Quality Definitions
• Quality:• Degree of excellence
• Conformance with requirements
• Totality of product features
• Fitness for use
• Freedom from defects, imperfections, or contamination
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Quality Definitions
• “Design process is a journey into the unknown, whereas the production process is a journey along a proven path with a predictable outcome” - David Hoyle, Quality Systems Handbook
• ISO 9001 requires: “establish procedures for identifying adequate statistical techniques required for verifying the acceptability product characteristics”
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Quality Definitions
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Images from:http://aerospaceengineeringblog.com/sandwich-panel/http://communicats.blogspot.co.uk/p/technical-art.html
Face sheets
Adhesive material
Core splicing
Core type 1
Core type 2 Core type 2
Insert
Quality Definitions
AM Aerospace Core
Manufacturing Design
Machine location?
Which process?
Manufacturing workflow?
Component optimisation?
Fulfilling requirements?
Design workflow?
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Customer Input
Quality Definitions
AM Aerospace Core
Manufacturing Design
Machine location?
Which process?
When in the process?
Component optimisation?
Fulfilling requirements?
Design workflow?
Quality Assurance
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Customer Input
Quality Definitions
AM Aerospace Core
Manufacturing Design
Quality Control
Machine location?
Which process?
When in the process?
Component optimisation?
Fulfilling requirements?
Design workflow?
Quality Assurance
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Customer Input
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Assuring Quality
• FDA – Technical Considerations for Additive Manufactured Devices• Draft guidance for qualifying medical devices
• Highlights need for documentation
• Separation of Geometry/Build certification
• Difficulties in inspection of internal defects and complex geometries
Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.Images: http://www.bbc.co.uk/news/technology-34044453http://www.wakehealth.edu/WFIRM/
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Assuring Quality
• Geometric Dimensions and Tolerancing (GD&T)• Common accuracy control
• Suited for 2D Shapes
Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.
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Assuring Quality
• Geometric Dimensions and Tolerancing (GD&T)
• Product and Manufacturing Information (PMI)• Complex curvatures
• Strong Process/Product interaction
• Not meant for human interpretation
Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.
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Assuring Quality
• Process inputs
• Thermal:• Contraction of layers during cooling
• Inter-layer bonding effects
• Mechanically induced:• Machine vibration
• Variable flow rates
Image: https://www.simplify3d.com/support/print-quality-troubleshooting/
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Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
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Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Layer thicknessSpeedFlow rateNozzle temperatureNozzle diameterPart orientationRaster angleInfill type/density
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
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Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Filament shape + sizeRheologyElastic modulus
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
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Assuring Quality
Process Parameters
Material Properties
Build Environment
AM Process Model[TODO – image]
Surface Roughness
Accuracy
Strength
Build time
Build cost
Density
Chamber temperatureMechanical responseAir properties
Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055
Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.
Thermal & Mechanical effects
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Assuring Quality
• Thermal distortion• Can cause separation from build surface
• Affects final accuracy
• Can be predicted and reduced based on model
• Thermal bonding• Layers bond above Tg
• Modelling of heat flow during print
Source: Huang, Q., Zhang, J., Sabbaghi, A. and Dasgupta, T., 2015. Optimal offline compensation of shape shrinkage for three-dimensional printing processes. IIE Transactions, 47(5), pp.431-441.
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Assuring Quality
• Thermal distortion modelling• Traditionally constrained my
CAD/Simulation tools
• Functional Generative Design:• Developed by Dassault Systèmes
• CATIA geometry
• Abaqus FEA
• Tosca topology optimisation
Image: http://perspectives.3ds.com/tag/functional-generative-design/Source: CompositesWorld September 2016, p13
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Assuring Quality
• Cores produced through FDM tested in compression
• Similar ultimate stress for wall thickness variation
• Different failure characteristics• Especially compared to Nomex
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Source: Pollard, D., Ward, C., Herrmann, G., Etches, J., 2016. Manufacture of Honeycomb Cores through Fused Deposition Modelling. Proceedings of the 17th European Conference on Composite Materials
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Progress in Control
• Flow control• Iterative Learning Control
• Different flow states discretised
• Road thickness variations used to modify input signal for next iteration
• 80% reduction of RMS error
Source: Hoelzle, D.J., Alleyne, A.G. and Johnson, A.J.W., 2009, June. Iterative Learning Control using a basis signal library. In 2009 American Control Conference (pp. 925-930). IEEE.
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Progress in Control
• Machine control• Majority of low-cost printers use open-
loop stepper motors
• With axis encoders and PI control, 75% reduction in tracking error for jagged contours
Source: Weiss, B.M., 2014. Closed-Loop Control of a 3D Printer Gantry (Doctoral dissertation, University of Washington).
NB: Errors radially amplified by 20x
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Progress in Control
• MarkForged X• Prints with carbon
reinforcement
• 50 µm resolution
• Laser scanner for part accuracy checks
Source: https://markforged.com/introducing-the-mark-x/
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Progress in Control
Additive/Subtractive manufacture
Source: Keating, S. and Oxman, N., 2013. Compound fabrication: A multi-functional robotic platform for digital design and fabrication. Robotics and Computer-Integrated Manufacturing, 29(6), pp.439-448.
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Progress in Control
Surface scanning and printing
Source: Song, X., Pan, Y. and Chen, Y., 2015. Development of a low-cost parallel kinematic machine for multidirectional additive manufacturing. Journal of Manufacturing Science and Engineering, 137(2), p.021005.:
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Progress in Control
Source: Song, X., Pan, Y. and Chen, Y., 2015. Development of a low-cost parallel kinematic machine for multidirectional additive manufacturing. Journal of Manufacturing Science and Engineering, 137(2), p.021005.
Full video available from: https://www.youtube.com/watch?v=qGyiXFGvkqE
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Progress in Control
• Superimposition of object over surface for 3D printing
• Identified key issues for multi-dimensional printing• Tight tolerance for nozzle positioning
• Requires stiff mechanical system
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Source: Bausch, N., Dawkins, D., Frei, R., Klein, S., 2016.3D Printing onto Unknown Uneven Surfaces. Proceedings of the 7th
IFAC Symposium on Mechatronic Systems
Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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AM Cores in Aerospace
• Optimisation of honeycomb cores for required loads• Reinforcement for higher stress concentrations
• Variations in cell density or shape around holes
• Curved panels production with no added complexity
Source: Riss, F., Schilp, J. and Reinhart, G., 2014. Load-dependent optimization of honeycombs for sandwich components–new possibilities by using additive layer manufacturing. Physics Procedia, 56, pp.327-335.
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AM Cores in Aerospace
• Boeing Patent US 2004/0048027• “Honeycomb Cores for Aerospace Applications”
• Discuss key advantages:• Reduces manufacturing cost for complex Radar
Cross Section
• Internal features and geometry
• Multiple gradients of material for testing reduction
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Source: Hayes, M., DeGrange, J., Rice, C. and Polus, J., Hayes Michael W., DegrangeJeffrey E., Rice Christian V. and Polus Jeffrey E., 2002. Honeycomb cores for aerospace applications. U.S. Patent Application 10/236,361.
AM Cores in Aerospace
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
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AM Cores in Aerospace
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
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AM Cores in Aerospace
Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
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AM Cores in Aerospace
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Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.
AM Cores in Aerospace
Source: Pollard, D., 2014, Automated sandwich panel production utilisingadditive manufacture and silicone pick and place technology, Masters Thesis, University of Bristol
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AM Cores in Aerospace
Source: Pollard, D., 2014, Automated sandwich panel production utilisingadditive manufacture and silicone pick and place technology, Masters Thesis, University of Bristol
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Contents
• Motivation
• Introduction
• Quality Definitions
• Assuring Quality
• Progress in Control
• AM Cores in Aerospace
• Further work
Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/
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Further work
• Efficient structure
• Manufacturability
• Increased functionality
Design optimisation
• Failure monitoring
• Reduction of manual input
• In-process quality control
Reliability in production
• Non Destructive Testing
• Quality Assurance/Control
• Advances in qualification processesPart verification
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Selection of further reading• Review papers:
• Huang, Y., Leu, M.C., Mazumder, J. and Donmez, A., 2015. Additive manufacturing: current state, future potential, gaps and needs, and recommendations. Journal of Manufacturing Science and Engineering, 137(1), p.014001.
• Huang, T., Wang, S. and He, K., 2015, October. Quality control for fused deposition modeling based additive manufacturing: Current research and future trends. In Reliability Systems Engineering (ICRSE), 2015 First International Conference on (pp. 1-6). IEEE.
• Guessasma, S., Zhang, W., Zhu, J., Belhabib, S. and Nouri, H., 2015. Challenges of additive manufacturing technologies from an optimisation perspective. International Journal for Simulation and Multidisciplinary Design Optimization, 6, p.A9.
• Modelling and Process Control:• Sun, Q., Rizvi, G.M., Bellehumeur, C.T. and Gu, P., 2008. Effect of processing conditions on the bonding quality of FDM polymer
filaments. Rapid Prototyping Journal, 14(2), pp.72-80
• Huang, Q., Nouri, H., Xu, K., Chen, Y., Sosina, S. and Dasgupta, T., 2014. Statistical predictive modeling and compensation of geometric deviations of three-dimensional printed products.Journal of Manufacturing Science and Engineering, 136(6), p.061008.
• Yoon, J., He, D. and Van Hecke, B., 2014, September. A PHM approach to additive manufacturing equipment health monitoring, fault diagnosis, and quality control. In Proceedings of the Prognostics and Health Management Society Conference, Fort Worth, TX, USA (Vol. 29, pp. 1-9).
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Acknowledgements
• Supervisors: Dr Carwyn Ward, Dr Guido Herrmann, Dr Julie Etches
• This work was supported by the EPSRC Centre for Doctoral Training in Future Autonomous Robotic Systems (FARSCOPE) at the Bristol Robotics Laboratory, (grant: EP/L015293/1).
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