ii - eprints.utem.edu.myeprints.utem.edu.my/5790/1/Mechanical_Properties_Of_Powder-Based_Part... · merupakan kunci kepada kebaikan-kabaikan penggunaan teknologi ini. Tesis ini Tesis

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“I hereby declare that this project report is written by me and is my own effort and that

no part has been plagiarized without citation”

Signature : ………………………………………..

Name of Writer : ………………………………………..

Date : ……………………………………….

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DEDICATION

To my parents, my supervisor and friends.

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ACKNOLEDGEMENT

First, author would like to express my gratitude to the supervisor Puan Siti Hajar

Bt Sheikh Md Fadzullah for her encouragement and support. Also thank you for

guidance along this project.

I also would like to thank to Puan Ruzy Haryati Bt Hambali for her support and

advise. For En. Fairuz who has given his time to teach me about the machine.

Lastly but not least this appreciation also wish to anyone whose was involved for

help this project. I hope that that this report will become source of references to students

in future.

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ABSTRACT

Rapid Prototyping (RP) is referred to as a class of technology that can

automatically build a physical model from (CAD) data. One of the rapid prototyping

technologies is explored via Three Dimensional Printing (3DP) Machine developed by

the Massachusetts Institute of Technology and license to Z Corporation, which is use

powder-based material. The capability of Three Dimensional Printing (3DP) are speedy

fabrication and low material cost. There were three types of specimen dimension, which

was design, and the Compression Testing as per ASTM D695 was done to investigate

the mechanical properties, which is Prism 1 (12.7x12.7x25.4) mm, Prism 2 (15x15x30)

mm and dog-bone (5 specimens for each type). The 3DP machine that was used to

produce the parts is ZPrinter 310 Plus and the material that the machine used is ZP130

for the powder and Zb58 for the binder. From the results that was obtained from the

compression testing, dog-bone specimen obtained the highest Compressive Strength at

4.43±0.623 MPa and also the highest Modulus of Elasticity at 1.71±0.143 GPa. In

comparison with prism 1 of 2.96±2.21 MPa for Compressive Strength and 1.26±0.259

GPa for Modulus of Elasticity and for prism 2 of 2.30±0.931 MPa for Compressive

Strength and 1.37±0.195 GPa for Modulus of Elasticity. From the results that were

analyzed, it can be concluded that the smallest cross-section area produce the highest

compressive strength, this is because binder is highly concentrated and absorbed into the

specimen.

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ABSTRAK

Rapid Prototyping merujuk kepada suatu bidang teknologi masa kini yang

mampu untuk menghasilkan model fizikal secara automatik berdasarkan data daripada

lukisan terbantu computer. Cepat menghasilkan produk dan kos bahan adalah rendah

merupakan kunci kepada kebaikan-kabaikan penggunaan teknologi ini. Tesis ini

bertujuan untuk mengkaji sifat-sifat mekanikal terutamanya daripada aspek mampatan

bagi sesuatu produk berasaskan powder-based yg dihasilkan melalui mesin 3DPrinter.

Penyelidikan ini melibatkan tiga jenis specimen iaitu lima unit bagi setiap specimen.

Prism 1 yang mempunyai dimensi 12.7mm x 12.7mm x 25.4 dan Prism 2 berdimensi

15mm x 15mm x30mm dan spesimen yang ketiga berbentuk dog-bone adalah merujuk

kepada Ujian Mampatan ASTM D695. Mesin jenis ZPrinter 310 Plus, bahan asas Zp30,

dan binder Zb58 adalah peralatan-peralatan yang terlibat secara langsung di dalam

penyelidikan ini. Berdasarkan keputusan yang diperolehi, specimen jenis dog-bone

mempunyai nilai kekuatan mampatan yang tertinggi iaitu 4.43±0.623MPa modulus

keanjalan dan 1.71±0.143GPa. Seterusnya, diikuti dengan Prism 1 dengan

2.96±2.21MPa nilai mampatan dan 1.26±0.259GPa untuk nilai modulus keanjalan.

Untuk Prism 2, nilai kekuatan mampatan adalah 2.30±0.931MPa and 1.37±0.195GPa

untuk Modulus keanjalan. Setelah kesemua keputusan yang diperolehi dianalisa,

kesimpulan yang dapat dibuat adalah semakin kecil keratan rentas, akan menghasilkan

nilai kekuatan mampatan yang tinggi kerana binder banyak diserap kedalam spesimen.

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LIST OF TABLE

NO. TITLE PAGE

1.0 Gantt Chart for the Research Activity in this Project. 5

2.1 Comparison of Rapid Prototyping 19

2.2 Rule of Thumb Miniature Feature Size 28

2.3 Type of 3D Printer 37

2.4 General Definition of Mechanical Properties 38

2.5 RapidSteel properties 38

2.6 Copper polyamide properties 40

2.7 Properties of bronze-based sintered powder and manufacturing

time and cost 41

2.8 Processing data and properties of Ref. and prepared by 3D-Printing

Al2O3/Cu-alloy composites 47

3.0 Dimension for each specimen 50

3.1 Identification of Chemical Substance and Company 50

3.2 Composition / information of Ingredients 51

3.3 Physical and Chemical Properties 52

3.4 Stability and reactivity 52

3.5 Identification of Chemical Substance and Company 53

3.6 Composition / information of Ingredients 53

3.7 Physical and Chemical Properties 54

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3.8 Stability and reactivity 55

3.9 Technical Specification for Zprinter 310 Plus 59

3.10 Dimension for each specimen 60

4.1 Experimental and Theoretical value of Yield Strength for

different type of specimen 64

4.2 Compressive Strength data from Experiment and Theoretical 68

4.3 Modulus of Elasticity data for Experiment and Theoretical 71

5.0 Experimental Result for Three different Type of Specimens 74

5.1 Table for Theoretical 75

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LIST OF FIGURE

NO. TITLE PAGE

2.1 Schematic diagram of stereolithography 12

2.2 Schematic diagram of laser sintering 13

2.3 Schematic diagram of FDM 14

2.4 Schematic diagram of 3D printing 14

2.5 Schematic diagram of laminated object manufacturing 15

2.6 Stairstepping 23

2.7 Surface finish for each type of RP 24

2.8 Surface Finish of Sculpture 25

2.9 Three-dimensional printing process 29

2.10 Gas-atomized (left) and water-atomized (right) 316L stainless

steel powder 32

2.11 Ink-jet printed, two-dimensional ZrO2 structure with 170 μm

resolution. The distance between the outer vertical surfaces of

adjacent walls is approximately 1 mm 33

2.12 Three-dimensional structures fabricated by direct ceramic

ink-jet printing. The optical image is shown on the left; the

SEM scan showing details is shown on the right 34

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3.0 Overview of research methodology 45

3.1 Flow process for the research design 46

3.2 Shape and dimensions specimen for compression test 48

3.3 Shape and dimensions specimen for compression test 49

3.4 Shape and dimensions specimen for compression test 55

3.5 3D Printer Machine 56

3.6 Flow Process of 3DP Processing 57

3.7 The process of 3D printer 60

3.8 Compression testing machine 60

4.1 Comparison chart for mean value of Yield Strength for

experiment and theory 65

4.2 Graph of Load versus Strain for each specimen. 66

4.3 Figure before and after compression testing 67

4.4 Chart for Mean Value of Compressive Strength 69

4.5 Experimental and Theoretical Mean Value of Compressive Strength 70

4.6 Mean Value of Compesssive Modulus each specimen 72

4.7 Mean Value of Compressive Modulus for Experimental and theoretical. 72

5.1 Type of the build direction. 77

5.2 Direction of the compression load for each type of build direction. 77

5.3 Figure before and after compression testing. 78

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TABLE OF CONTENT

CHAPTER INDEX PAGE

DECLARATION ii

DEDICATION iii

ACKNOLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

LIST OF TABLE vii

LIST OF FIGURE ix

TABLE OF CONTENT xi

CHAPTER 1 INTRODUCTION

1.1 Rapid Prototyping 2

1.2 Three Dimensional Printer 4

1.3 Aim of Work 4

1.4 Problem Statement 4

1.5 Planning Execution 5

CHAPTER 2 LITERATURE REVIEW

2.1 Rapid Prototyping 6

2.1.1 Type of RP technique 12

2.1.2 Basic Process 15

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2.1.3 Comparison of RP Technique 17

2.2 Three Dimensional Printer 27

2.2.1 Basic Process 29

2.3 Material 30

2.3.1 Powder Based 31

2.3.1.1 Metal Powder 31

2.3.1.2 Ceramic Powder 33

2.4 Mechanical Properties 36

2.4.1 Mechanical Properties of Part Produce 37

from Metal Powder

2.4.2 Mechanical Properties of Part Produce 42

from Polymer Powder

2.4.3 Mechanical Properties of Part Produce 43

from Ceramic Powder

CHAPTER 3 METHODOLOGY

3.1 Research Design 44

3.2 Design of Test Specimen 46

3.2.1 Design of experiment 47

3.2.2 Design of Test Specimen Via 47

SolidWorks

3.3 Raw Material 49

3.4 3D Pinter 54

3.4.1 Processing 56

3.5 Mechanical Testing 58

3.5.1 Compression Test as per ASTM D695 58

3.5.1.1 Equipment/ Testing Apparatus 59

3.5.1.2 Testing Parameter 60

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CHAPTER 4 RESULT AND ANALYSIS

4.1 Stress-strain Relationship of Part Produce from 63

3-D Printer under Compression Force

4.2 Compressive Strength of Part Produce from 68

3-D Printer

4.3 Compressive Modulus of Part Produce from 70

3-D Printer

CHAPTER 5 DISCUSSION 73

CHAPTER 6 CONCLUSION 80

CHAPTER 7 SUGGESSTION AND RECOMMENDATION 81

FOR FUTURE WORKS

REFFERENCES 82

BIBLIOGRAFI 85

APPENDIX 87

1

CHAPTER I

INTRODUCTION

Rapid Prototyping (RP) is a technology that provides the ability to build or

fabricate prototypes for initial design of a product. There are various materials can be

used in producing the prototypes needed, which depends on the RP machine itself. For

3D-Printer Machine, it actually can be simplified as a commercial RP process. Various

process parameters can be found in 3D-printer which affects the character of RP parts;

including build direction, layer thickness, temperature and so on. Layer thickness

actually refers to the thickness of each part being produced by the 3D-Printer Machine.

Before any products become a product that can be use in human life, one sample

or prototype required as a specimen. This is because the sample will used to allow for

demonstration, evaluation or testing for the proposed product. The technology that used

to make the prototype is define as Rapid Prototyping (RP) and usually come first before

a specific mold tool and jigs are design. For make prototyping traditionally required skill

of employee, time and cost. These three causes usually applied for cutting, bending,

shaping and assembly the part that needed.

The procedure was often iterative, with a series of prototypes being built to test

various options. For many applications, this process has been revolutionized by a

relatively recent technology known as layer manufacturing or Solid Freeform

Fabrication(SFF) which is any part from any shape, can be produced in a single process

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by adding successive layers of material. Usually mold, jigs and die are also include the

quickly fabrication of the tools required for mass production. Now, there are many

different manufacturing process have develop using an increasing the range of material

[1,].

1.1 Rapid Prototyping

Rapid Prototyping (RP) is referred to as a class of technology can automatically

build a physical model from Computer-Aided Design (CAD) data. This technology

make designer quickly create prototypes of their design, although just two dimension

pictures [1, 2, 3, 5, 7, 9,10]. Prototype can also be used in design testing. Other than

that, RP also can be use to make tooling and any production part. RP is usually best

manufacturing process for small production runs and complicated object. Most

producing prototype take shortly time, but the time that required depends on the size and

the complexity of the object. This process rather consumes more time make the

prototype but still better than conventional method such as machining. Rapid

prototyping system is a technology that emerges in 1980s. During the modern concept of

Rapid prototyping was conceived and developed; actually the origin of this technology

is back to the 1890s [1]. This is some of the most popular and commonly used RP

technique [3,10]:

i. Selective laser sintering (SLS)

ii. Fused Deposition Modeling (FDM)

iii. Stereolithography (SLA)

iv. Multi Jet Modeling (MJM)

v. Laminated Object Manufacturing (LOM)

vi. Electron Beam Melting (EBM)

vii. 3D Printing (3DP)

viii. Objet PolyJet Modeling

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1.2 Three -dimensional Printer

Three-Dimensioning printing refers to a category of rapid technology which is

converting a virtual 3D model to become a physical object. Typically, 3D printer is an

extremely flexible system, capable of creating part of any shape using any material

including ceramics, metals, polymers and composites. 3D printer also generally faster

and easier to use than other additive technologies. Three-dimensional printing (3DP)

developed by the Massachusetts Institute of Technology and licensed to Z Corporation

of Burlington, Massachusetts. The material usually use in this system is limited to two

choices: plaster or starch.

Usually the material that is recommended is the plaster based because it is more

durable and gives better resolution. Starch should be used if need making investment

mold. After finish printing the part, it should be infiltrated. Infiltrants that are used to

wax includes cyanoacrylate (superglue) and Z Max epoxy [4].

A unique capability of three-dimensional printing is the ability to produce

multicolored parts. A part’s color is determined by dyes added to the liquid binder.

Almost any color is possible. Each layer, in essence, is like a full-color image printed on

a flat sheet of paper by an ink-jet printer

Three dimensional printing offers the advantages of speedy fabrication and low

materials cost. In fact, it's probably the fastest of all RP methods. Recently color output

has also become available. However, there are limitations on resolution, surface finish,

part fragility and available materials. The closest competitor to this process is probably

fused deposition modeling [2,10].

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1.3 Aim of Works

The objective in this project is:

To design and fabricate part from powder- based material using 3D printer.

To investigate the mechanical properties of part produced.

The scope in this project is:

To design a part from powder- based material used in rapid prototyping.

To fabricate part using 3d printer machine.

To investigate the mechanical properties of part including compression test as

per ASTM D695.

1.4 Problem Statement

This research is dedicated to the study of particularly for compression behavior

of part which produces using 3D-Printer Machine. From the literature review, many

researches reported about the specimen dimension, technical specification of machine

but very few resources have reported about mechanical properties of powder-based part

produced from the 3D Printer.

1.5 Planning and Execution

Table 1 below depicts the research activity that is carried out throughout the

project. The first four months is dedicated to the literature review and design of the

experiment (DOE) that cover the research methodology.

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Table 1.0: Gantt Chart for the Research Activity in this Project.

Research

Activity/Time W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13

PSM 1

Problem Statement

Literature Review

Rapid Prototyping

3D Printer

Raw Material used

Mechanical

Properties

Methodology

Experimental review

Research Design

DOE

RP Process

Mechanical Testing

Design of Test

Specimen

Report Writing

Submission Report

PSM 2

Literature Review

RP/3D Printer

Raw Material

Mechanical

Properties

Methodology

Produce Specimen

Procedure of

Mechanical Testing

Mechanical testing

Compression Test

Result & Findings

Report Writing

Submission report

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CHAPTER II

LITERATURE REVIEW

2.1 Rapid Prototyping

Rapid Prototyping (RP) refers to a group of technologies that can fabricate

physical, three dimensional part of arbitrary shape directly from Computer Aided Design

(CAD) and Computer Aided Manufacturing (CAM) by fully automated, fast and highly

flexible process [2, 5, 7, 8, 9, 10]. According to the Wohler Report (2004), Rapid

Prototyping refers to fabricate a physical model of a design using digital driven, additive

processes. RP also produce model very quickly from 3D CAD data, CT and MRI scans,

and data from 3D digitizing system. This means, Rapid Prototyping method can save the

processing time and also save cost producing the prototype than using conventional

technique for fabricating physical model which can be more expensive and also time

consuming which may take a few days or even weeks [2, 5].

Rapid Prototyping was emerged in 1980’s, where the high technology was

conceived, developed and promote in 1980’s. 1890’s is the date of the origin technology.

For the early history for rapid prototyping, it’s also known a layered manufacturing.

This is because of the concept for building something using layer by layer at

least two technical areas: topography and photosculpture. In that time, the method used

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to produce tool or even prototype and usually the product that have produce in small

quantities [2].

This technology allow designer quickly create prototypes of their design,

although just two dimension pictures. Designer will makes the prefect visual aids for

show their ideas to their co-workers and also to customers. Prototype usually numerous

use such as, it can be use in design testing. Other than that, RP also can be use to make

tooling and any production part. RP is usually best manufacturing process for small

production runs and complicated object. Most producing prototype take shortly time,

but the time that required depends on the size and the complexity of the object.

RP system has it own advantages such as; prototype that required can build even

though the prototype has a complex shape. It also builds the prototype without setting

the arrangement of the machine. Besides that, RP also build the prototype using multiple

materials by available technique. Other than that, RP has reduced time to market. Cut

trial cost and improved the quality of the product.

RP have become an important part of the product development process. By using

RP has time taken can be reduced, cut cost and improve the quality of the product. This

means, RP allowed user do and fabricate the design and prototype to verify before they

involve in the expensive tooling and fabrication of mass production. Below are several

type of application in education and industry [2].

i. Application in Product Development

In this new era of global for providing product and service, RP

technology become one of the medium that make the process become

easier. This is because all the company involve in product development

and manufacturing will face with the competition to bring the product to

market faster, cheaper and also with high quality functioning. In this

problem, RP is the best solution for the problem that help all companies

by reduce the cycle of product development and also during making the

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design for making improvement of the product. The most application can

be dividing into three major categories:

a) Prototype Design Evaluation

b) Prototype for Function Verification

c) Prototype for Manufacturing Process Validation

ii. Application in Reverse Engineering

Reverse Engineering is science by taking the physical model and produce

it surface geometry in 3D data file on CAD file. RE is the faster way to

get 3D data into any computer system. The example for this application is

situation includes hand made prototypes, craft work, dental application

and reproduction of old engineering object.

iii. Application in Casting and Pattern Making

This application is important for casting and pattern making. Casting

allows fabricate complex shape but for the simple shape machining can

be used.

iv. Application in Rapid Tooling

According to the rapid solution web, Rapid tooling is using a rapid

prototype, either indirectly or directly, as a tooling pattern for creating a

mold. Rapid tooling techniques enable you to have molds with the

correct material at a substantially reduced cost in a fraction of the time it

takes to produce parts from production tooling processes. The greater the

complexity of the part, is the greater the benefits of cost and time.

v. Application in Medical

Application in medical is one of the most successful applications for

rapid manufacturing. For the example this application is used to the

production of customized hearing aids. This is because every ear is

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different, and the size of the parts makes it possible to fabricate the

products in large, economical batches with existing equipment.

vi. Application in Rapid Manufacturing

a. In Rapid manufacturing, there are still having a lot of challenges for the

limitation of speed, material and accuracy. But by using the rapid

prototyping technology most of the companies show the

successfully[2,3,7,9]

According to Rochus, et.al (2007) their article was reported rapid prototyping

and manufacturing are known to be destructive technologies. Everyday industry used of

this method has increase rapidly. The principal of this technology of manufacturing parts

is layer by layer starting from liquid, paste or powder. After the material is deposited,

the selecting surface is treated according to a process define by the chosen technique in

order to solidify a cross section of the final component. This process are applied for

prototyping, small series, injection moulds manufacturing, mock-ups and also used in

several engineering sectors. In their article also state the general description for the rapid

prototyping technique such as, Stereolithography (SLA), Selective Laser Sintering (SLS)

and Jet Based Technology. The start with a 3D CAD model, then the model need to

convert to the stereolithography (STL) format. Only this format can be read by the

machine. This is because the format will change dividing the model into layer form. By

dividing the object into the layer form, the machine will printed the object layer by layer

according to the STL format. This process is continuously until the layer becomes an

object.

It is reported from in their article, rapid prototyping is a innovative technology

develop rapidly and very useful for industry. The aim of this technology is to produce

prototype relatively quickly. Most the RP system is now commercially available. There

are three type of system that can be classified according to the material used which is

powder based, resin based and sheet based. For powder based, the RP process includes

the Selective Laser Sintering (SLS) and 3D Printing process. Resin based process such

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as Stereolithography (SLA) and the laminated sheet based process included the

Laminated Object Manufacturing (LOM) process. Generally all the principal of process

are similar but the things that make the technique different are the materials that use to

make prototyping. In this paper also mention the advantage of this technology such a

reducing time and cost. This is because, all the process will make the prototype in the

short time than the traditionally method. And also can produce more prototypes in one

time. Besides that, this technology make the cost reduce by making the prototype in

exactly as the real one. But, this technology has the limitation such as the quality and

accuracy. But not all the system of RP has this problem [Choi,et al (2003)].

According to Durham. (2003) Rapid Prototyping is very useful in industry. This

is because RP is a powerful tool to reducing time to market and it also improving quality

and reducing cost. He also said the challenge is during selecting the suitable process that

need to use. During making decision for what process that need to choose, the important

thing that needs to consider is combination with the intended material. This is because;

selecting a process without considering the material will yield the questionable result. In

his article also state the RP process that usually used in industry which is,

Stereolithography (SLA), Selective Laser Sintering (SLS) and also PolyJet. In this

article also mention comparison the process as the material available for each.

Stereolithography (SLA) process is used material in liquid resin. The process is using

ultraviolet laser to solidify the material. Although the SLA is limited in its range of

applicable material, it is suitable for conceptual visualization. Selective Laser Sintering

(SLS), the material is from powder material. The SLS process create the object by

heating the powder using heat from a carbon dioxide laser fuses (sinter). The advantage

for this process is more widely using in industry and also suitable for function analysis.

Hatsopoulos, (2000) wrote that Rapid Prototyping introduces a method that is

called “3D Printing”. Before this, the model making take too much time and the cost is

high. Also the technique is always limited for use. But it is less expensive and faster

when using 3D printing method. From this, this technology give the designer better

access to model, which is provide the freedom to make many more of model. This