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Research Papers: Design Theory and Methodology

A Conceptual Design and Modeling Framework for Integrated Additive Manufacturing

[+] Author and Article Information
Hossein Mokhtarian

Mem. ASME
Mechanical Engineering and Industrial Systems,
MEI Laboratory,
Tampere University of Technology,
P.O. Box: 589,
Tampere 33101, Finland;
University Grenoble Alpes,
CNRS,
G-SCOP laboratory 46 Avenue Félix Viallet,
GRENOBLE Cedex 1 38031, France
e-mail: Hossein.mokhtarian@tut.fi

Eric Coatanéa

Mechanical Engineering and Industrial Systems,
MEI Laboratory,
Tampere University of Technology,
P.O. Box: 589,
Tampere 33101, Finland
e-mail: Eric.coatanea@tut.fi

Henri Paris

University Grenoble Alpes,
CNRS,
G-SCOP laboratory 46 Avenue Félix Viallet,
GRENOBLE Cedex 1 38031, France
e-mail: henri.paris@g-scop.inpg.fr

Mouhamadou Mansour Mbow

University Grenoble Alpes,
CNRS,
G-SCOP laboratory 46 Avenue Félix Viallet,
GRENOBLE Cedex 1 38031, France
e-mail: mouhamadou-mansour.mbow@grenoble-inp.fr

Franck Pourroy

University Grenoble Alpes,
CNRS,
G-SCOP laboratory 46 Avenue Félix Viallet,
GRENOBLE Cedex 1 38031, France
e-mail: franck.pourroy@g-scop.inpg.fr

Philippe René Marin

University Grenoble Alpes,
CNRS,
G-SCOP laboratory 46 Avenue Félix Viallet,
GRENOBLE Cedex 1 38031, France
e-mail: Philippe.marin@g-scop.inpg.fr

Jorma Vihinen

Mechanical Engineering and Industrial Systems,
MEI Laboratory,
Tampere University of Technology,
P.O. Box: 589,
Tampere 33101, Finland
e-mail: jorma.vihinen@tut.fi

Asko Ellman

Mechanical Engineering and Industrial Systems,
MEI Laboratory,
Tampere University of Technology,
P.O. Box: 589,
Tampere 33101, Finland
e-mail: asko.ellman@tut.fi

Contributed by the Design Theory and Methodology Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received January 31, 2017; final manuscript received April 27, 2018; published online May 23, 2018. Assoc. Editor: Carolyn Seepersad.

J. Mech. Des 140(8), 081101 (May 23, 2018) (13 pages) Paper No: MD-17-1076; doi: 10.1115/1.4040163 History: Received January 31, 2017; Revised April 27, 2018

Modeling and simulation for additive manufacturing (AM) is commonly used in industry. Nevertheless, a central issue remaining is the integration of different models focusing on different objectives and targeting different levels of details. The objective of this work is to increase the prediction capability of characteristics and performances of additively manufactured parts and to co-design parts and processes. The paper contributes to this field of research by integrating part's performance model and additive technology process model into a single early integrated model. The paper uses the dimensional analysis conceptual modeling (DACM) framework in an AM perspective to generate causal graphs integrating the AM equipment and the part to be printed. DACM offers the possibility of integrating existing knowledge in the model. The framework supported by a computer tool produces a set of governing equations representing the relationships among the influencing variables of the integrated model. The systematic identification of the weaknesses and contradictions in the system and qualitative simulation of the system are some of the potential uses of the model. Ultimately, it is a way to create better designs of machines and parts, to control and qualify the manufacturing process, and to control three-dimensional (3D) printing processes. The DACM framework is tested on two cases of a 3D printer using the fused filament fabrication (FFF) powder bed fusion. The analysis, applied to the global system formed of the 3D printer and the part, illustrates the existence of contradictions. The analysis supports the early redesign of both parts and AM process (equipment) and later optimization of the control parameters.

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Figures

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Fig. 1

Visual representation of DACM framework approach

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Fig. 2

Representation of the generic variables and their interconnections in the bond graph theory

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Fig. 3

An algorithm for extracting causality between assigned variables in DACM

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Fig. 4

A representation of DACM framework on RLC circuit case study with the different transformations. Left: concept space, generic functional model. Right: knowledge space, extracted causal graph for the circuit.

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Fig. 5

Functional model and generated causal graph by analogy between three energy domains (electrical, hydraulic, thermal)

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Fig. 6

A presentation of the DACM framework using the CK theory organization of the design process with the concept and knowledge spaces. The dimensionless numbers are the result of the application of the DACM framework to the beam topology optimization problem.

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Fig. 7

A: typical machine liquefier, B: thermal interfaces between block materials in RepRap liquefier, C: geometry of the part to be manufactured

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Fig. 8

Systematic transformation between interface analysis (A), functional model (B), and generic functional representation (C) and extracting causal graph for thermal heat exchange in FFF liquefier

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Fig. 9

Partial causal graph of FFF liquefier and the part to be manufactured (Qualitative objectives are underlined. The backward propagations on the graph are shown with the same colors).

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Fig. 10

Printing result before and after process parameter modification

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Fig. 11

A presentation of DACM framework for curling defect modeling (DACM for DFAM support)

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