Additive manufacture of cores for aerospace: Linking ...€¦ · Additive manufacture of cores for...

Additive manufacture of cores for aerospace: Linking quality

and controlDavid Pollard - [email protected] - 20th October 2016

SAMPE UK and Ireland Chapter 2016 Masterclass – Additive Manufacture

The Manufacturing Technology Centre, Ansty Park, Coventry

Contents

• Motivation

• Introduction

• Quality Definitions

• Assuring Quality

• Progress in Control

• AM Cores in Aerospace

• Further work

Images from:http://airinsight.com/2011/09/06/first-a350-xwb-flyable-wing-upper-cover/http://www.designboom.com/technology/dx-toronto-3dxl-large-scale-3d-printing-05-15-2015/

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Contents

• Motivation

• Introduction





• Further work


3

Motivation

Source: http://www.3ders.org/articles/20160323-airbus-seeks-to-3d-print-half-of-its-future-airplane-fleet.html

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Motivation

• Aurora Flight Science and Stratasys collaboration

• Demonstrates feasibility of custom aircraft• Reduced cost

• Faster design time

Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciences

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Motivation

• Faster design iterations• 50% Design and Build time

reduction

• 80% AM components

• ULTEM FDM Plastic• Meets FAA Flame, Smoke, and

Toxicity (FST) requirements

Source: http://www.stratasys.com/resources/case-studies/aerospace/aurora-flight-sciences

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Motivation

• Impossible Objects:• Composites Based Additive Manufacture (CBAM)

• Laminate-based method for long-fibre reinforcement printing

• Collaboration with Aurora Flight Sciences• Produced AM stabilisers capable of taking

landing load

Source: http://www.compositesworld.com/articles/3d-printed-composite-parts-provide-solution-for-uav

CompositesWorld: September 2016

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Contents

• Motivation

• Introduction





• Further work


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Introduction

• Processes• Vat Polymerisation

• Powder Bed Fusion

• Binder Jetting

• Material Jetting

• Sheet Lamination

• Material Extrusion

• Directed Energy Deposition

• ASTM F2792:• “process of joining materials to make

objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies”

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Introduction

• Google Trends:• Search terms:

• 3D printing (Industry)

• Manufacturing (Industry)

• 3D printing was more commonly used than Additive Manufacturing

• Results are the percentage of peak searches

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Introduction

3D printing (Industry)

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% o

f p

eak

sear

ches

Introduction

3D printing (Industry)

Manufacturing (Industry)

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% o

f p

eak

sear

ches

Introduction

Bel

ief

Time

13

Introduction

Bel

ief

Time

14

Introduction

Bel

ief

Time

15

Introduction

Bel

ief

Time

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Introduction

Source: European Commission Report:Identifying current and future application areas, existing industrial value chains and missing competences in the EU, in the area of additive manufacturing (3D-printing)

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Introduction

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Ridged print failure - nozzle blockage

Sprue – insufficient retraction to stop flowSupport structures

Peeling from print bed

Contents

• Motivation

• Introduction





• Further work


19

Quality Definitions

• Quality:• Degree of excellence

• Conformance with requirements

• Totality of product features

• Fitness for use

• Freedom from defects, imperfections, or contamination

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Quality Definitions

• “Design process is a journey into the unknown, whereas the production process is a journey along a proven path with a predictable outcome” - David Hoyle, Quality Systems Handbook

• ISO 9001 requires: “establish procedures for identifying adequate statistical techniques required for verifying the acceptability product characteristics”

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Quality Definitions

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Images from:http://aerospaceengineeringblog.com/sandwich-panel/http://communicats.blogspot.co.uk/p/technical-art.html

Face sheets

Adhesive material

Core splicing

Core type 1

Core type 2 Core type 2

Insert

Quality Definitions

AM Aerospace Core

Manufacturing Design

Machine location?

Which process?

Manufacturing workflow?

Component optimisation?

Fulfilling requirements?

Design workflow?

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Customer Input

Quality Definitions

AM Aerospace Core


Machine location?

Which process?

When in the process?



Design workflow?

Quality Assurance

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Customer Input

Quality Definitions

AM Aerospace Core


Quality Control

Machine location?

Which process?

When in the process?



Design workflow?

Quality Assurance

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Customer Input

Contents

• Motivation

• Introduction





• Further work


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Assuring Quality

• FDA – Technical Considerations for Additive Manufactured Devices• Draft guidance for qualifying medical devices

• Highlights need for documentation

• Separation of Geometry/Build certification

• Difficulties in inspection of internal defects and complex geometries

Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.Images: http://www.bbc.co.uk/news/technology-34044453http://www.wakehealth.edu/WFIRM/

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Assuring Quality

• Geometric Dimensions and Tolerancing (GD&T)• Common accuracy control

• Suited for 2D Shapes

Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.

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Assuring Quality

• Geometric Dimensions and Tolerancing (GD&T)

• Product and Manufacturing Information (PMI)• Complex curvatures

• Strong Process/Product interaction

• Not meant for human interpretation

Source: Witherell, P., Herron, J., & Ameta, G. (2016). Towards Annotations and Product Definitions for Additive Manufacturing. Procedia CIRP, 43, 339-344.

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Assuring Quality

• Process inputs

• Thermal:• Contraction of layers during cooling

• Inter-layer bonding effects

• Mechanically induced:• Machine vibration

• Variable flow rates

Image: https://www.simplify3d.com/support/print-quality-troubleshooting/

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Assuring Quality

Process Parameters

Material Properties

Build Environment

AM Process Model[TODO – image]

Surface Roughness

Accuracy

Strength

Build time

Build cost

Density

Image: By Zureks - Own work, GFDL, https://commons.wikimedia.org/w/index.php?curid=5544055

Source: Garg, A., Tai, K. and Savalani, M.M., 2014. State-of-the-art in empirical modelling of rapid prototyping processes. Rapid Prototyping Journal, 20(2), pp.164-178.

Thermal & Mechanical effects

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Assuring Quality

Process Parameters

Material Properties

Build Environment


Surface Roughness

Accuracy

Strength

Build time

Build cost

Density

Layer thicknessSpeedFlow rateNozzle temperatureNozzle diameterPart orientationRaster angleInfill type/density




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Assuring Quality

Process Parameters

Material Properties

Build Environment


Surface Roughness

Accuracy

Strength

Build time

Build cost

Density

Filament shape + sizeRheologyElastic modulus




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Assuring Quality

Process Parameters

Material Properties

Build Environment


Surface Roughness

Accuracy

Strength

Build time

Build cost

Density

Chamber temperatureMechanical responseAir properties




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Assuring Quality

• Thermal distortion• Can cause separation from build surface

• Affects final accuracy

• Can be predicted and reduced based on model

• Thermal bonding• Layers bond above Tg

• Modelling of heat flow during print

Source: Huang, Q., Zhang, J., Sabbaghi, A. and Dasgupta, T., 2015. Optimal offline compensation of shape shrinkage for three-dimensional printing processes. IIE Transactions, 47(5), pp.431-441.

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Assuring Quality

• Thermal distortion modelling• Traditionally constrained my

CAD/Simulation tools

• Functional Generative Design:• Developed by Dassault Systèmes

• CATIA geometry

• Abaqus FEA

• Tosca topology optimisation

Image: http://perspectives.3ds.com/tag/functional-generative-design/Source: CompositesWorld September 2016, p13

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Assuring Quality

• Cores produced through FDM tested in compression

• Similar ultimate stress for wall thickness variation

• Different failure characteristics• Especially compared to Nomex

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Source: Pollard, D., Ward, C., Herrmann, G., Etches, J., 2016. Manufacture of Honeycomb Cores through Fused Deposition Modelling. Proceedings of the 17th European Conference on Composite Materials

Contents

• Motivation

• Introduction





• Further work


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Progress in Control

• Flow control• Iterative Learning Control

• Different flow states discretised

• Road thickness variations used to modify input signal for next iteration

• 80% reduction of RMS error

Source: Hoelzle, D.J., Alleyne, A.G. and Johnson, A.J.W., 2009, June. Iterative Learning Control using a basis signal library. In 2009 American Control Conference (pp. 925-930). IEEE.

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Progress in Control

• Machine control• Majority of low-cost printers use open-

loop stepper motors

• With axis encoders and PI control, 75% reduction in tracking error for jagged contours

Source: Weiss, B.M., 2014. Closed-Loop Control of a 3D Printer Gantry (Doctoral dissertation, University of Washington).

NB: Errors radially amplified by 20x

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Progress in Control

• MarkForged X• Prints with carbon

reinforcement

• 50 µm resolution

• Laser scanner for part accuracy checks

Source: https://markforged.com/introducing-the-mark-x/

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Progress in Control

Additive/Subtractive manufacture

Source: Keating, S. and Oxman, N., 2013. Compound fabrication: A multi-functional robotic platform for digital design and fabrication. Robotics and Computer-Integrated Manufacturing, 29(6), pp.439-448.

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Progress in Control

Surface scanning and printing

Source: Song, X., Pan, Y. and Chen, Y., 2015. Development of a low-cost parallel kinematic machine for multidirectional additive manufacturing. Journal of Manufacturing Science and Engineering, 137(2), p.021005.:

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Progress in Control

Source: Song, X., Pan, Y. and Chen, Y., 2015. Development of a low-cost parallel kinematic machine for multidirectional additive manufacturing. Journal of Manufacturing Science and Engineering, 137(2), p.021005.

Full video available from: https://www.youtube.com/watch?v=qGyiXFGvkqE

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https://www.youtube.com/watch?v=qGyiXFGvkqE

Progress in Control

• Superimposition of object over surface for 3D printing

• Identified key issues for multi-dimensional printing• Tight tolerance for nozzle positioning

• Requires stiff mechanical system

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Source: Bausch, N., Dawkins, D., Frei, R., Klein, S., 2016.3D Printing onto Unknown Uneven Surfaces. Proceedings of the 7th

IFAC Symposium on Mechatronic Systems

Contents

• Motivation

• Introduction





• Further work


46

AM Cores in Aerospace

• Optimisation of honeycomb cores for required loads• Reinforcement for higher stress concentrations

• Variations in cell density or shape around holes

• Curved panels production with no added complexity

Source: Riss, F., Schilp, J. and Reinhart, G., 2014. Load-dependent optimization of honeycombs for sandwich components–new possibilities by using additive layer manufacturing. Physics Procedia, 56, pp.327-335.

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• Boeing Patent US 2004/0048027• “Honeycomb Cores for Aerospace Applications”

• Discuss key advantages:• Reduces manufacturing cost for complex Radar

Cross Section

• Internal features and geometry

• Multiple gradients of material for testing reduction

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Source: Hayes, M., DeGrange, J., Rice, C. and Polus, J., Hayes Michael W., DegrangeJeffrey E., Rice Christian V. and Polus Jeffrey E., 2002. Honeycomb cores for aerospace applications. U.S. Patent Application 10/236,361.


Source: White, J., Etches, J. Ward, C., 2013. CDE 28088: The Development of Low Cost Additive Layer Manufacturing for Use as Repair Equipment in the Field, to Improve Operations and Support for Composite Platforms.

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Source: Pollard, D., 2014, Automated sandwich panel production utilisingadditive manufacture and silicone pick and place technology, Masters Thesis, University of Bristol

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Source: Pollard, D., 2014, Automated sandwich panel production utilisingadditive manufacture and silicone pick and place technology, Masters Thesis, University of Bristol

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Contents

• Motivation

• Introduction





• Further work


55

Further work

• Efficient structure

• Manufacturability

• Increased functionality

Design optimisation

• Failure monitoring

• Reduction of manual input

• In-process quality control

Reliability in production

• Non Destructive Testing

• Quality Assurance/Control

• Advances in qualification processesPart verification

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Selection of further reading• Review papers:

• Huang, Y., Leu, M.C., Mazumder, J. and Donmez, A., 2015. Additive manufacturing: current state, future potential, gaps and needs, and recommendations. Journal of Manufacturing Science and Engineering, 137(1), p.014001.

• Huang, T., Wang, S. and He, K., 2015, October. Quality control for fused deposition modeling based additive manufacturing: Current research and future trends. In Reliability Systems Engineering (ICRSE), 2015 First International Conference on (pp. 1-6). IEEE.

• Guessasma, S., Zhang, W., Zhu, J., Belhabib, S. and Nouri, H., 2015. Challenges of additive manufacturing technologies from an optimisation perspective. International Journal for Simulation and Multidisciplinary Design Optimization, 6, p.A9.

• Modelling and Process Control:• Sun, Q., Rizvi, G.M., Bellehumeur, C.T. and Gu, P., 2008. Effect of processing conditions on the bonding quality of FDM polymer

filaments. Rapid Prototyping Journal, 14(2), pp.72-80

• Huang, Q., Nouri, H., Xu, K., Chen, Y., Sosina, S. and Dasgupta, T., 2014. Statistical predictive modeling and compensation of geometric deviations of three-dimensional printed products.Journal of Manufacturing Science and Engineering, 136(6), p.061008.

• Yoon, J., He, D. and Van Hecke, B., 2014, September. A PHM approach to additive manufacturing equipment health monitoring, fault diagnosis, and quality control. In Proceedings of the Prognostics and Health Management Society Conference, Fort Worth, TX, USA (Vol. 29, pp. 1-9).

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Acknowledgements

• Supervisors: Dr Carwyn Ward, Dr Guido Herrmann, Dr Julie Etches

• This work was supported by the EPSRC Centre for Doctoral Training in Future Autonomous Robotic Systems (FARSCOPE) at the Bristol Robotics Laboratory, (grant: EP/L015293/1).

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