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Repeatability of Additive Manufactured Parts
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.
2017 (English)Independent thesis Basic level (degree of Bachelor), 10 credits / 15 HE creditsStudent thesis
Abstract [en]

Saab Surveillance in Järfä̈lla constructs complex products, such as radars and electronic support measures. Saab sees an advantage in manufacturing details with additive manufacturing as it enables a high level of complexity. Additive manufacturing is relatively new in the industry and consequently there are uncertainties regarding the process. The purpose of this bachelor thesis was to improve the knowledge of the repeatability of additive manufactured parts as well as compare additive manufactured test rods in two different directions, horizontally and vertically, to subtractive manufactured test rods with a vibration test. The vibration test was conducted to simulate the operative environment where the additive manufactured parts might be implemented in the future. Before the vibration test could be performed, the test rods were designed in a 3D-modeling program and analysed with a finite element method to achieve the required natural frequency range of 100 - 200 Hz and a maximal bending stress of 60 - 80 MPa in the notched area of the test rod.

It was concluded that the subtractive manufactured test rods had the highest repeatability. The horizontally additive manufactured test rods had a higher repeatability than the vertically additive manufactured test rods, but the vertically additive manufactured test rods had the highest overall strength. It was also concluded that more studies are needed to ensure that additive manufactured parts can be produced with high repeatability while maintaining the structural integrity. 

Abstract [sv]

Saab Surveillance i Järfä̈lla konstruerar komplexa försvarsprodukter som till exempel radarsystem. Additiv tillverkning i metall möjliggör tillverkning av produkter med hög komplexitet, men då tillverkningsprocessen är relativt ny i industrin finns det en stor osäkerhet kring processen. Syftet med detta kandidatexamensarbete var att få en bättre förståelse för repeterbarheten hos additivt tillverkade delar samt att jämföra additivt tillverkade provstavar konstruerade i två olika riktningar, horisontellt och vertikalt, med svarvade provstavar med hjälp av ett vibrationstest. Vibrationstestet genomfördes för att simulera den operativa miljön där de additivt tillverkade detaljerna skulle kunna implementeras i framtiden. Innan vibrationstestet kunde utföras simulerades provstavarnas design i en mjukvara för 3D-modellering. En finit element-analys utfördes även fö̈r att få en egenfrekvens inom intervallet 100 - 200 Hz och en maximal böjspänning mellan 60 - 80 MPa i anvisningen på provstaven.

Slutsatsen drogs att de traditionellt bearbetade stavarna hade den högsta repeterbarheten. De horisontellt additivt tillverkade stavarna hade högre repeterbarhet än de vertikalt additivt tillverkade stavarna, men att de vertikalt additivt tillverkade stavarna hade ett längre utmattningsliv. Det kunde även konstateras att fler studier inom ämnet behövs för att kunna säkerställa repeterbarheten hos additivt tillverkade delar utan att behöva kompromissa med hållfastheten. 

Place, publisher, year, edition, pages
2017.
Keywords [en]
Additive Manufacturing, 3D-printing, Repeatability, Vibration Test, Aluminium Alloy
Keywords [sv]
Additiv tillverkning, 3D-printing, Repeterbarhet, Vibrationstest, Aluminiumlegering
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:kth:diva-209804OAI: oai:DiVA.org:kth-209804DiVA, id: diva2:1114555
External cooperation
Saab AB
Educational program
Master of Science in Engineering - Materials Design and Engineering
Presentation
Jernkontoret (English)
Supervisors
Examiners
Available from: 2017-06-28 Created: 2017-06-24 Last updated: 2017-08-21Bibliographically approved

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