12/14/2024
AM Numerical
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Numerical
A prototype of a tube with a square cross-section is to be
fabricated using stereolithography. The outside dimension of the
square = 100 mm, and the inside dimension = 90 mm (wall
thickness = 5 mm except at corners). The height of the tube (z-
direction) = 80 mm. Layer thickness = 0.10 mm. The diameter of
the laser beam (“spot size”) = 0.25 mm, and the beam is moved
across the surface of the photopolymer at a velocity of 500 mm/s.
Compute an estimate for the time required to build the part; if 10
seconds are lost, each layer lowers the height of the platform that
holds the part. Neglect the time for post-curing.
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
1
12/14/2024
Numerical
•In a selective laser melting process, the scanning speed was kept equal to 500 mm/s,
laser power was 100 W, hatch spacing was 0.2 mm and layer thickness was 0.08 mm.
During the building of the part, it was observed that the energy density was not sufficient
for sintering of the metal particles. Therefore, the energy density was doubled to affect
the scan speed, keeping other parameters constant. If the material requires, 20 J/mm3.
Calculate the following –
• Energy density after increment
New scanning velocity
Excess/deficient energy
BITS Pilani, Pilani Campus
Numerical
A solid part (see figure) of polymer material is to be fabricated by additive
manufacturing (AM) in square-shaped layers starting from the bottom of the part
working upwards. The nozzle diameter of the (AM) machine is a/10 mm and the
nozzle follows a linear serpentine path parallel to the sides of the square layers
with a feed rate of a/5 mm/min.
Ignore any tool path motions other than those involved in adding material, and any
other delays between layers or the serpentine scan lines.
The time taken to fabricate this part is ____________ minutes.
BITS Pilani, Pilani Campus
2
12/14/2024
Numerical
In a powder feed AM system , the steel metal is injected using an off-
axis nozzle at an angle of 60° from vertical through a nozzle of
diameter 5mm; if the laser power is 1kW, find out the catchment
efficiency of the process. Given Tm=1425°C, To=25°C, k= 50 W/mK.
ɳ = 10.34%
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
Numerical
In a powder feed-based AM Process, the side feeding nozzle is used
to feed material into the molten pool. If with the same setup and
laser power the material is changed from A to B. And the melting
point of materials A and B is the same, but the thermal conductivity
of material B is 4 times higher than the thermal conductivity of
material A; find out the ratio of catchment efficiencies of both
materials.
ɳA/ɳB = 16
BITS Pilani, Deemed to be University under Section 3 of UGC Act, 1956
3
12/14/2024
Numerical
A manufacturer is using a laser-based metal powder bed fusion
machine (cost: USD 10 lakhs) for the fabrication of a part (200 mm
× 200 mm × 200 mm). The average time taken by the recoater for
placing a new layer (layer thickness 25 µm) was 9 s. The laser beam
scans the powder layer in raster pattern with a speed of 300 mm/s
and 0.1 mm hatch spacing. Calculate/discuss with respect to the
building of a single part –
(a) Total recoating time (s),
(b) Total recoating cost (USD),
(c) Total hatching time (s),
(d) Total hatching cost (USD),
BITS Pilani, Pilani Campus
Machine hourly running costs =
(Machine purchase cost + interest)/(payback period × % running time × yearly hours)
BITS Pilani, Pilani Campus
