A Comprehensive Approach to Digital Manufacturing

Description

This book draws a comprehensive approach to digital manufacturing through computer-aided design (CAD) and reverse engineering content complemented by basic CNC machining and computer-aided manufacturing (CAM), 3D printing, and additive manufacturing (AM) knowledge. The reader is exposed to a variety of subjects including the history, development, and future of digital manufacturing, a comprehensive look at 3D printing and AM, a comparative study between 3D printing and AM and CNC machining, and computer-aided engineering (CAE) along with 3D scanning. Applications of 3D printing and AM are presented as well as multiple special topics including design for 3D printing and AM (DfAM), costing, sustainability, environmental, safety, and health (EHS) issues. Contemporary subjects such as bio-printing, intellectual property (IP) and engineering ethics, virtual prototyping including augmented, virtual, and mixed reality (AR/VR/MR), and industrial Internet of Things (IIoT) are also covered. Each chapter comes with in-practice exercises and end-of-chapter questions, which can be used as home-works as well as hands-on or software-based laboratory activities. End-of-chapter questions are of three types mainly: review questions which can be answered by reviewing each chapter, research questions which need to be answered by conducting literature reviews and additional research, and discussion questions. In addition, some of the chapters include relevant problems or challenges which may require additional hands-on efforts. Most of the hands-on and practical content is driven by the authors’ previous experiences. The authors also encourage readers to help improve this book and its exercises by contacting them. Preface Acknowledgements Contents About the Authors 1 Introduction 1.1 What is Digital Manufacturing? 1.2 Role of Digital Manufacturing in Product Design and Development 1.3 Historical Evolution from Rapid Prototyping to Additive Manufacturing 1.4 Comparison of 3D Printing and Additive Manufacturing to Computer Numerically Controlled (CNC) Machining References 2 Preparation for 3D Printing and CNC Machining 2.1 Computer-Aided Design (CAD) Subjects Relevant to 3D Printing and CNC Machining 2.1.1 Wireframe Modeling Including Analytical and Free-Form Curves 2.1.2 Surface Modeling 2.1.3 Solid Modeling References 3 Computer-Aided Manufacturing (CAM) 3.1 Historical Background of Numerical Control (NC) and CNCs 3.2 Operating Principle of NC 3.2.1 Control Systems 3.3 CNC Turning and Machining Centers 3.3.1 Axes Designations 3.4 Introduction to CNC Programming 3.4.1 In-Process Gauging 3.4.2 CNC Machine Calibration with Ballbar and Laser Measurements 3.4.3 Principles of Interferometry—The Michelson Interferometer 3.5 Introduction to CAM 3.5.1 Workflow of a CAM System References 4 3D Printing Pre-processing 4.1 Introduction to 3D Printing and AM 4.2 Designing in CAD 4.3 Design for 3D Printing and Additive Manufacturing (DfAM) 4.3.1 AM Design Constraints 4.4 Intermediate File Format Generation 4.5 Slicing and Support Generation References 5 3D Printing Processes and Associated Materials 5.1 Solid Raw Material Based Processes 5.1.1 Fused Deposition Modeling/Fused Filament Fabrication 5.1.2 Continuous Filament Fabrication 5.1.3 Bound Metal Deposition 5.1.4 Wire Arc Additive Manufacturing 5.1.5 Laminated Object Manufacturing 5.1.6 Ultrasonic Additive Manufacturing 5.1.7 Liquid Raw Material Based Processes 5.1.8 Stereolithography (SLA/SL) 5.1.9 Digital Light Processing (DLP) 5.1.10 PolyJet Process 5.2 Powder Raw Material Based Processes 5.2.1 Binder Jetting 5.2.2 Multi Jet Fusion (MJF) 5.2.3 Selective Laser Sintering (SLS) 5.2.4 Direct Metal Selective Laser Sintering (DMLS) 5.2.5 Selective Laser Melting (SLM) 5.2.6 Electron Beam Melting (EBM) 5.2.7 Laser Engineered Net Shape Process (LENS®) 5.2.8 Recent Developments in Metal 3D Printing 5.3 Other Processes 5.3.1 RAPIDIA Process References 6 3D Printing Post Processing 6.1 Removal of Supports and Cleaning 6.2 Finishing Processes 6.2.1 Post Process for Material Extrusion (FDM/FFF) 6.2.2 Post Processing of SLS Parts References 7 Applications of 3D Printing 7.1 Rapid Prototyping 7.2 Rapid Tooling 7.2.1 Direct and Indirect Rapid Tooling 7.3 Additive (Rapid) Manufacturing 7.4 Non-industrial Applications of 3D Printing 7.4.1 Preserving Historical Artifacts 7.4.2 Food Printing 7.4.3 Medical Applications References 8 Computer-Aided Engineering (CAE) and Industrial Internet of Things (IIoT) 8.1 Introduction to IoT/IIoT 8.1.1 IoT Systems Architecture 8.1.2 IoT Use Cases 8.1.3 Present State and Future of IoT 8.2 CAE for Virtual Prototyping, and Digital Twins 8.2.1 Introduction to Numerical Methods 8.2.2 CAE for Manufacturing Processes 8.2.3 CAE for Manufacturing Systems 8.2.4 Digital Twins References 9 Reverse Engineering 9.1 Reverse Engineering Methodology 9.2 Reverse Engineering Technology 9.2.1 2D Scanners and the Photogrammetry Process 9.2.2 3D Scanners 9.3 Intellectual Property Laws and Ethics 9.4 Non-industrial Use Cases References 10 Special Topics in Digital Manufacturing 10.1 Cost Modeling and Estimation for 3D Printing and Additive Manufacturing 10.1.1 A Cost Model for the FFF Process 10.1.2 Building the Case for Business 10.2 Sustainability and Environmental Issues for 3D Printing and Additive Manufacturing 10.3 Health, and Safety Issues of 3D Printing and Additive Manufacturing 10.4 Multiple Realities for IIoT and Industrial Training 10.4.1 Virtual Simulation 10.4.2 Augmented Reality 10.4.3 Augmented Virtuality (Virtual Reality) 10.4.4 Comparing and Contrasting XR Hardware 10.4.5 Industrial and Educational Applications 10.4.6 Applications and Software Tools of the Looking Glass Hologram 10.4.7 The Future of Multiple Realities References 11 Practicum 11.1 Product Development and Manufacturing Project 11.2 Reverse Engineering Project 11.3 Automating Additive Manufacturing References Appendix I: G&M Codes Appendix II: G&M Codes for 3D Printing Appendix III: Purdue University AM Scorecard