Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing
Thesis: S.M., Massachusetts Institute of Technology, Department of Mechanical Engineering, May, 2020
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| Format: | Thesis |
| Language: | eng |
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Massachusetts Institute of Technology
2020
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| Online Access: | https://hdl.handle.net/1721.1/127160 |
| _version_ | 1826194340817403904 |
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| author | Gee, Kaitlyn Elizabeth. |
| author2 | A. John Hart. |
| author_facet | A. John Hart. Gee, Kaitlyn Elizabeth. |
| author_sort | Gee, Kaitlyn Elizabeth. |
| collection | MIT |
| description | Thesis: S.M., Massachusetts Institute of Technology, Department of Mechanical Engineering, May, 2020 |
| first_indexed | 2024-09-23T09:54:31Z |
| format | Thesis |
| id | mit-1721.1/127160 |
| institution | Massachusetts Institute of Technology |
| language | eng |
| last_indexed | 2024-09-23T09:54:31Z |
| publishDate | 2020 |
| publisher | Massachusetts Institute of Technology |
| record_format | dspace |
| spelling | mit-1721.1/1271602020-09-04T03:37:07Z Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing Gee, Kaitlyn Elizabeth. A. John Hart. Massachusetts Institute of Technology. Department of Mechanical Engineering. Massachusetts Institute of Technology. Department of Mechanical Engineering Mechanical Engineering. Thesis: S.M., Massachusetts Institute of Technology, Department of Mechanical Engineering, May, 2020 Cataloged from the official PDF of thesis. Includes bibliographical references (pages 81-84). AM expands the design space in an unprecedented manner, as it can allow complex internal geometries, support multiple materials or structural gradients, significantly reduce lead times for small-batch production, and enable mass customization [1]. However, the adoption of AM in industry is hindered by our lack of design knowledge and inability to navigate the myriad considerations required to reliably produce high quality AM components economically. To quantitatively assess the tradeoffs between build rate, resolution and cost for AM processes, we present a physics-based rate and cost estimator for scanning laser based AM. The model takes a mesh representation of the part design as input, and uses a parametrized model of the rate-limiting physics of the build process to estimate the part-specific build time [2] [3]. From this build time estimate, per-part cost is calculated using a quantity-dependent activity-based model [4]. The model thus enables parametric analysis of tradeoffs between part quality (e.g., resolution), throughput, and cost. Additionally, we develop an analytical model to quantify the number of melting cycles the part undergoes during the print process as a metric of print quality. Integrated with our physics-based build time estimator, we articulate the tradeoff between build rate and print quality as a direct function of material properties, machine specifications, and print parameter selection. By conceptualizing and quantifying the relationships between part design, manufacturability, and cost, the computational design and decision-making tools developed here will enable optimal use of AM in real-world, production contexts. Given the complexity of designing for AM, these results produce valuable insight into otherwise complicated relationships between rate, cost and quality for SLM. For industry, this work will enable faster, cost-effective product production by identifying the most desirable print parameter sets. by Kaitlyn Elizabeth Gee. S.M. S.M. Massachusetts Institute of Technology, Department of Mechanical Engineering 2020-09-03T17:49:58Z 2020-09-03T17:49:58Z 2020 2020 Thesis https://hdl.handle.net/1721.1/127160 1191844347 eng MIT theses may be protected by copyright. Please reuse MIT thesis content according to the MIT Libraries Permissions Policy, which is available through the URL provided. http://dspace.mit.edu/handle/1721.1/7582 84 pages application/pdf Massachusetts Institute of Technology |
| spellingShingle | Mechanical Engineering. Gee, Kaitlyn Elizabeth. Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing |
| title | Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing |
| title_full | Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing |
| title_fullStr | Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing |
| title_full_unstemmed | Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing |
| title_short | Numerical tools for rate-cost-quality analysis of laser-based additive manufacturing |
| title_sort | numerical tools for rate cost quality analysis of laser based additive manufacturing |
| topic | Mechanical Engineering. |
| url | https://hdl.handle.net/1721.1/127160 |
| work_keys_str_mv | AT geekaitlynelizabeth numericaltoolsforratecostqualityanalysisoflaserbasedadditivemanufacturing |