Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes
Metal additive manufacturing (AM) has become a predominant process for manufacturing complex metal parts. However, research on controlling the geometric tolerances of the metal AM printed parts and assemblies is scarce. This paper presents a methodology to conduct a geometric tolerance and manufactu...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2020-09-01
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| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127520303762 |
| _version_ | 1811194051134750720 |
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| author | Baltej Singh Rupal Nabil Anwer Marc Secanell Ahmed Jawad Qureshi |
| author_facet | Baltej Singh Rupal Nabil Anwer Marc Secanell Ahmed Jawad Qureshi |
| author_sort | Baltej Singh Rupal |
| collection | DOAJ |
| description | Metal additive manufacturing (AM) has become a predominant process for manufacturing complex metal parts. However, research on controlling the geometric tolerances of the metal AM printed parts and assemblies is scarce. This paper presents a methodology to conduct a geometric tolerance and manufacturing assemblability study of the parts manufactured by metal AM. An assembly benchmark test artifact (ABTA) is designed to include mating features with given assembly conditions based on geometric tolerancing quantifiers. For virtual analysis, prediction phase ABTA samples are generated by using systematic and random field theory deviations. The prediction phase deviations are then calibrated using deviations from a numerical simulation based on thermo-mechanical finite element model of the part. These samples or ‘skin model shapes’ are subjected to geometric tolerance and assemblability study. For experimental validation of the method, geometric tolerance quantification and actual assembly was conducted on laser powder bed fusion (LPBF) fabricated parts. The comparative analysis of the experimental and virtual results validates the new methodology and its ability to provide reliable information regarding assemblability, size dimensions and geometric tolerances. The method can be extended to any AM process for performing a virtual tolerance and manufacturing assemblability study. |
| first_indexed | 2024-04-12T00:19:20Z |
| format | Article |
| id | doaj.art-a2ae5a962d8641e0b316753138d31c44 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-04-12T00:19:20Z |
| publishDate | 2020-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-a2ae5a962d8641e0b316753138d31c442022-12-22T03:55:45ZengElsevierMaterials & Design0264-12752020-09-01194108842Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processesBaltej Singh Rupal0Nabil Anwer1Marc Secanell2Ahmed Jawad Qureshi3Additive Design and Manufacturing Systems (ADaMS) Lab, Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta T6G 1H9, Canada; Université Paris-Saclay, ENS Paris-Saclay, LURPA, 94235 Cachan, France; Energy Systems Design Lab (ESDL), Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta T6G 1H9, CanadaUniversité Paris-Saclay, ENS Paris-Saclay, LURPA, 94235 Cachan, FranceEnergy Systems Design Lab (ESDL), Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta T6G 1H9, CanadaAdditive Design and Manufacturing Systems (ADaMS) Lab, Department of Mechanical Engineering, University of Alberta, Edmonton, Alberta T6G 1H9, Canada; Corresponding author.Metal additive manufacturing (AM) has become a predominant process for manufacturing complex metal parts. However, research on controlling the geometric tolerances of the metal AM printed parts and assemblies is scarce. This paper presents a methodology to conduct a geometric tolerance and manufacturing assemblability study of the parts manufactured by metal AM. An assembly benchmark test artifact (ABTA) is designed to include mating features with given assembly conditions based on geometric tolerancing quantifiers. For virtual analysis, prediction phase ABTA samples are generated by using systematic and random field theory deviations. The prediction phase deviations are then calibrated using deviations from a numerical simulation based on thermo-mechanical finite element model of the part. These samples or ‘skin model shapes’ are subjected to geometric tolerance and assemblability study. For experimental validation of the method, geometric tolerance quantification and actual assembly was conducted on laser powder bed fusion (LPBF) fabricated parts. The comparative analysis of the experimental and virtual results validates the new methodology and its ability to provide reliable information regarding assemblability, size dimensions and geometric tolerances. The method can be extended to any AM process for performing a virtual tolerance and manufacturing assemblability study.http://www.sciencedirect.com/science/article/pii/S0264127520303762Additive manufacturingLaser powder bed fusionGeometric dimensioning and tolerancingFinite element methodSkin model shapesDesign for additive manufacturing |
| spellingShingle | Baltej Singh Rupal Nabil Anwer Marc Secanell Ahmed Jawad Qureshi Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes Materials & Design Additive manufacturing Laser powder bed fusion Geometric dimensioning and tolerancing Finite element method Skin model shapes Design for additive manufacturing |
| title | Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes |
| title_full | Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes |
| title_fullStr | Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes |
| title_full_unstemmed | Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes |
| title_short | Geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing (AM) processes |
| title_sort | geometric tolerance and manufacturing assemblability estimation of metal additive manufacturing am processes |
| topic | Additive manufacturing Laser powder bed fusion Geometric dimensioning and tolerancing Finite element method Skin model shapes Design for additive manufacturing |
| url | http://www.sciencedirect.com/science/article/pii/S0264127520303762 |
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