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S. J. B Institute of Technology: Mini-Project Report
S. J. B Institute of Technology: Mini-Project Report
S. J. B Institute of Technology: Mini-Project Report
B INSTITUTE OF TECHNOLOGY
B G S HEALTH AND EDUCATION CITY,
Kengeri, Bangalore-560060.
Mini-Project Report
on
Submitted
By
Dr.Satheesh J
Professor
Department of Mechanical Engineering
Sri Adichunchanagiri Shikshana Trust ®
S. J. B INSTITUTE OF TECHNOLOGY
BGS Health & Education City, Kengeri, Bangalore-560060.
CERTIFICATE
Guide HOD
Dr. Satheesh J Dr.T Madhusudan
[Professor]
ACKNOWLEDGEMENT
I would like to express our profound homage to His Divine Soul Sri Sri Sri
this esteemed Institution and nurtured to take the right path in the society. My humble
pranams to His Holiness Jagadguru Sri Sri Sri Dr.Nirmalanandanatha Maha Swamiji
and Revered Sri Sri Dr.Prakashnatha Swamiji for bestowing their blessings.
I have immense pleasure in acknowledging the guidance and support of our respected
Principal Dr.Puttaraju, who is the source of support and guidance for all activities in this
Institution.
Mechanical Engineering, for providing valuable support and guidance in this project work.
Mechanical Engineering, for his guidance, suggestions and encouragement to carry out this
I also thank all the faculty members and technical staff of SJBIT for their support.
Last but not the least I am greatly indebted to my parents for providing this opportunity.
Regards,
Deepak B H
Department of Mechanical Engineering SJBIT
TERMINOLOGY
The umbrella term additive manufacturing (AM) gained wide currency in the
2000s, inspired by the theme of material being added together (in any of various
ways). In contrast, the term subtractive manufacturing appeared as
a heteronym for the large family of machining processes with
material removal as their common theme. The term 3D printing still referred
only to the polymer technologies in most minds, and the term AM was likelier
to be used in metalworking and end use part production contexts than among
polymer, inkjet, or stereo lithography enthusiasts. By the early 2010s, the
Mech Mantra: E= I2 Education = Innovation X Implementation Page 1
Department of Mechanical Engineering SJBIT
BRIEF HISTORY
Early additive manufacturing equipment and materials were developed in the
1980s. In 1981, Hideo Kodama of Nagoya Municipal Industrial Research
Institute invented two additive methods for fabricating three-dimensional plastic
models with photo-hardening thermoset polymer, where the UV exposure area
is controlled by a mask pattern or a scanning fibre transmitter.
which converts the model into a series of thin layers and produces a G code file
containing instructions tailored to a specific type of 3D printer. This G code file
can then be printed with 3D printing client software (which loads the G-code,
and uses it to instruct the 3D printer during the 3D printing process). Printer
resolution describes layer thickness and X-Y resolution in dots per inch (dpi) or
micrometres (μm). Typical layer thickness is around 100 m (250DPI), although
some machines can print layers as thin as 16 m (1,600DPI).X-Y resolution is
comparable to that of laser printers .The particles (3Ddots) are around 50 to
100m (510 to 250 DPI) in diameter. Higher resolution creates larger files. For
an STL file type, a mesh resolution of 0.01-0.03 mm and a≤0.016mm chord
length produce optimal results in the print of the part. Construction of a model
with contemporary methods can take anywhere from several hours to several
days, depending on the method used and the size and complexity of the model.
Additive systems can typically reduce this time to a few hours, although it
varies widely depending on the type of machine used and the size and number
of models being produced simultaneously. Traditional techniques like injection
moulding can be less expensive for manufacturing polymer products in high
quantities, but additive manufacturing can be faster, more flexible and less
expensive when producing relatively small quantities of parts.3D printers give
designers and concept development teams the ability to produce parts and
concept models using a desktop size printer. Seemingly paradoxical, more
complex objects can be cheaper for 3D printing production than less complex
objects.
3D PRINTING PROCESSES
There are a variety of processes and equipment used in the synthesis of a three-
dimensional object. 3D printing is also known as additive manufacturing,
therefore the numerous available 3D printing processes tend to be additive in
nature with a few key differences. The main areas in which these processes
differ are the technologies used in the process and the materials.
The variety of processes and equipment allows for numerous uses by amateurs
and professionals alike. Some lend themselves better toward industry use whilst
others make 3D printing accessible to the average consumer. Some printers are
large enough to fabricate buildings whilst others tend to micro and Nano scale
sized objects.
Fused deposition modelling (FDM), derives from automatic polymeric foil hot
air welding system, hot-melt gluing and automatic gasket deposition. Such
principle has been further developed by S. Scott Crump in the late 1980s and
was commercialized in 1990 by Stratasys.After the patent on this technology
expired, a large open-source development community developed and both
commercial and DIY variants utilizing this type of 3D printer appeared. As a
result, the price of this technology has dropped by two orders of magnitude
since its creation, and it has become the most common form of 3D printing.
Plastic is the most common material for such printing. Various polymers may
be used, including acrylonitrile butadiene styrene , polycarbonate , polylactic
acid high-density polyethylene PC/ABS, polyphenylsulfone and polystyrene In
general, the polymer is in the form of a filament fabricated from virgin resins.
There are multiple projects in the open-sourced community aimed at processing
post-consumer plastic waste into filament. These involve machines used to
shred and extrude the plastic material into filament. Additionally,
fluoropolymers such as PTFE tubing are used in the process due to the
material's ability to withstand high temperatures. This ability is especially useful
in transferring filaments.
Metal and glass may both be used as well, though they are much more
expensive and generally used for works of art.
shoppers. "There's real sense that this is not going to happen anytime soon," she
says, "but it will happen, and it will create dramatic change in how we think
both about intellectual property and how things are in the supply chain." She
adds: "Certainly some of the fabrications that brands can use will be
dramatically changed by technology."
In cars, trucks, and aircraft, AM is beginning to transform both (1) unibody and
fuselage design and production and (2) power train design and production. For
example: In early 2014, Swedish super car manufacturer Koenigsegg announced
the One: 1 a super car that utilizes many components that were 3D printed.
Urbee is the name of the first car in the world car mounted using the technology
3D printing (its body work and car windows were" printed"). In 2014, Local
Motors debuted Strati, a functioning vehicle that was entirely 3D Printed using
ABS plastic and carbon fibre, except the power train .In May 2015 Airbus
announced that its new Airbus A350XWB included over 1000 components
manufactured by 3Dprinting. In 2015, a Royal Air Force Euro fighter Typhoon
fighter jet flew with printed parts. The United States Air Force has begun to
work with 3D printers, and the Israeli Air Force has also purchased a 3D printer
to print spare part. In 2017, GE Aviation revealed that it had used design for
additive manufacturing to create a helicopter engine with 16 parts instead of
900, with great potential impact on reducing the complexity of supply chains.
3D printing, and open source 3D printers in particular, are the latest technology
making inroads into the classroom. Some authors have claimed that 3D printers
offer an unprecedented "revolution" in STEM education. The evidence for such
claims comes from both the low cost ability for rapid prototyping in the
classroom by students, but also the fabrication of low-cost high-quality
scientific equipment from open hardware designs forming open-source
labs. Future applications for 3D printing might include creating open-source
scientific equipment. In the last several years 3D printing has been intensively
used by in the cultural heritage field for preservation, restoration and
dissemination purposes. Many Europeans and North American Museums have
purchased 3D printers and actively recreate missing pieces of their relics.
The Metropolitan Museum of Art and the British Museum have started using
their 3D printers to create museum souvenirs that are available in the museum
shops. Other museums, like the National Museum of Military History and
Varna Historical Museum, have gone further and sell through the online
platform Threading digital models of their artefacts, created using Artec
3D scanners, in 3D printing friendly file format, which everyone can 3D print at
home.
RAPID PROTOTYPING
Rapid prototyping is a group of techniques used to quickly fabricate a scale
model of a physical part or assembly using three-dimensional computer aided
design (CAD) data. Construction of the part or assembly is usually done
using 3D printing or "additive layer manufacturing" technology.
The first methods for rapid prototyping became available in the late 1980s and
were used to produce models and prototype parts. Today, they are used for a
wide range of applications and are used to manufacture production-quality parts
in relatively small numbers if desired without the typical unfavourable short-run
economics. This economy has encouraged online service bureaus. Historical
surveys of RP technology start with discussions of simulacra production
techniques used by 19th-century sculptors. Some modern sculptors use the
progeny technology to produce exhibitions. The ability to reproduce designs
from a dataset has given rise to issues of rights, as it is now possible to
interpolate volumetric data from one-dimensional images.
this data must represent a valid geometric model; namely, one whose boundary
surfaces enclose a finite volume, contain no holes exposing the interior, and do
not fold back on themselves. In other words, the object must have an "inside".
The model is valid if for each point in 3D space the computer can determine
uniquely whether that point lies inside, on, or outside the boundary surface of
the model. CAD post-processors will approximate the application vendors'
internal CAD geometric forms (e.g., B-splines) with a simplified mathematical
form, which in turn is expressed in a specified data format which is a common
feature in additive manufacturing: STL (stereo lithography) a de facto standard
for transferring solid geometric models to SFF machines. To obtain the
necessary motion control trajectories to drive the actual SFF, rapid
prototyping, 3D printing or additive manufacturing mechanism, the prepared
geometric model is typically sliced into layers, and the slices are scanned into
lines (producing a "2D drawing" used to generate trajectory as in CNC's tool
path), mimicking in reverse the layer-to-layer physical building process. The
term rapid prototyping (RP) refers to a class of technologies that are used to
produce physical objects layer-by-layer directly from computer-aided design
(CAD) data. These techniques allow designers to produce tangible prototypes of
their designs quickly, rather than just two-dimensional pictures. Besides visual
aids for communicating ideas with co-workers or customers, these prototypes
can be used to test various aspects of their design, such as wind tunnel tests and
dimensional checks. In addition to the production of prototypes, rapid
prototyping techniques can also be used to produce moulds or mould inserts
(rapid tooling) and even fully functional end use parts (rapid manufacturing).
Because these are non-prototyping applications, rapid prototyping is often
referred to as solid free-form fabrication or layered manufacturing. For small
series and complex parts, these techniques are often the best manufacturing
processes available. They are not a solution to every part fabrication problem.
After all, CNC technology and injection moulding are economical, widely
The disc influences the force of the arm, which makes up the frame of reference
of the quick return mechanism. The frame continues to an attached rod, which is
connected to the circular disc. Powered by a motor, the disc rotates and the arm
follows in the same direction (linear and left-to-right, typically) but at a
different speed. When the disc nears a full revolution, the arm reaches its
furthest position and returns to its initial position at a quicker rate, hence its
name. Throughout the cut, the arm has a constant velocity. Upon returning to its
initial position after reaching its maximum horizontal displacement, the arm
reaches its highest velocity.
The quick return mechanism was modeled after the crank and slider (arm), and
this is present in its appearance and function; however, the crank is usually hand
powered and the arm has the same rate throughout an entire revolution, whereas
the arm of a quick return mechanism returns at a faster rate. The "quick return"
Mech Mantra: E= I2 Education = Innovation X Implementation Page 17
Department of Mechanical Engineering SJBIT
allows for the arm to function with less energy during the cut than the initial
cycle of the disc.
Shaper
Screw press
Power-driven saw
Mechanical actuator
Revolver mechanisms
Rotary Engines
Water pumping system