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unit5

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meenuthakur088
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UNIT 5

PROCESS SELECTION PLANNING

Dr. O. P. Mishra
SYLLABUS: UNIT 5

• Process Selection Planning,


• Control for AM: Selection of AM technologies using selection,
• Decision methods Additive manufacturing process plan: strategies and
post processing.
• Monitoring and control of defects, transformation
INTRODUCTION : PROCESS SELECTION

• The initial purpose of rapid prototyping technology was to create parts as a means of
visual and tactile communication.
• Now, the applications of additive manufacturing processes have expanded
considerably.
• AM processes, like all materials processing, are constrained by material properties,
speed, cost, and accuracy.
• Still Conventional Manufacturing is far better option.
• With the growth of AM, there is going to be increasing demand for software that
supports making decisions regarding which machines to use and their capabilities and
limitations for a specific part design.
PARTS FROM AM MACHINES ARE USED

• Visual aids
• Presentation models
• Functional models
• Fit and assembly
• Patterns for prototype tooling
• Patterns for metal castings
• Tooling components
• Direct digital/rapid manufacturing
MAIN ISSUES IN SELECTION PROCESS

• Three typical problems involving AM that may benefit from decision


support:
• 1. Quotation support: Given a part, which machine and material
should I use to build?
• 2. Capital investment support: Given a design and industrial profile,
what is the best machine that I can buy to fulfill my requirements?
• 3. Process planning support : Given a part and a machine, how do I
set it up to work in the most efficient manner alongside my other
operations and existing tasks?
SELECTION METHODS FOR A PART :
DECISION THEORY

• Decision theory is evolving in the 1940s and 1950s from the field of
economics.
• Broadly speaking, there are three elements of any decision;
• l Options – the items from which the decision maker is selecting,
• lI Expectations – of possible outcomes for each option, and
• IIl Preferences – how the decision maker values each outcome
DECISION THEORY : OPTIONS

• Assume that the set of decision options is denoted as A ¼ {A1, A2, ...,
An}.
• Criteria based evaluation of outcomes the options.
• outcome might consist of the time, cost, and surface finish of a part
built using a certain AM process.
• outcomes are modelled as functions of the options, X ¼ g(A), and may
be modelled with associated uncertainties
DECISION THEORY : PREFERENCES MODEL

• Preferences model is the importance assigned to outcomes by the


decision makers.
• For example, a designer may prefer low cost and short turn-around
times for a concept model, while being willing to accept poor surface
finish.
• Typically, weights are specified for each preference.
• The best alternative is the one with the greatest expected utility.
APPROACHES TO DETERMINING FEASIBILITY

• The problem of determining process and material feasibility can be represented by


the Preliminary Selection Decision Support Problem (PS-DSP).
• This is a structured decision formulation and corresponds to a formal decision
method based on decision theory.
• The key step in the ps-DSP is how to capture and apply experience-based
knowledge.
• Qualitative comparisons are performed, where a concept is judged as better, worse,
or about the same (þ1, 1, 0, respectively) as the datum with respect to the principal
criteria for the selection problem. Then, a weighted sum of comparisons with the
datum is computed.
RANKING

• 1.Given: a set of concepts


• 2. Identify: The principal criteria influencing selection. The relative
importance of the criteria
• 3.Capture: Experience-based knowledge about the concepts with
respect to a datum and the established criteria.
• 4. Rank: The concepts in order of preference based on multiple criteria
and their relative importance.
CHALLENGES OF SELECTION

• The complex relationships among attributes, and the variations that


can arise when building a wide range of parts make
• it difficult to decouple decision attributes and develop structured
decision problems.
• Nonetheless, with a proper understanding of technologies and
attributes, and how to relate them together, meaningful information
can be gained. This section takes a brief look at these issues.
• Cost issues to be considered. In AM costly and Cheaper machines and
processes are required.
EXAMPLE SYSTEM FOR PRELIMINARY
SELECTION
• A preliminary selection tool was developed for Direct Digital
Manufacturing (DDM), called DDMS, applications that walks the user
through a series of questions to identify feasible processes and
machines.
HELP FROM DESIGN SOFTWARE

• Explore AM technologies for their application in a possible DDM project,


• Identify candidate materials and processes,
• Explore build times, build options, costs,
• Explore manufacturing and life-cycle benefits of AM,
• Select appropriate AM technologies for DDM applications.
• Explore case studies, anticipate benefits
• Support Quotation and Capital Investment decisions
PRODUCTION PLANNING AND CONTROL

• 1. Production Planning : Several related decision are needed early in


the process. A suitable AM process and machine must be identified
from among those in the facility.
• A job scheduling system should be used, particularly for production
manufacturing applications, so that part batches can be produced to
meet deadline.
• 2. Pre-processing Preprocessing means software-based manipulation.
This will be carried out on the file that describes the geometry of the
part. Such manipulation can generally be divided into 2 areas,
modification of the design and determination of build parameters.
PART BUILD

• For some processes, like FDM or LENS, it does not really matter in terms of
time whether parts are built one after another (batches of 1) or parts are
grouped together in batches.
• However, most processes will vary significantly regarding this factor.
• This may be due to significant preparation time before the build process takes
place (such as powder bed heating in SLS), or because there is a significant
delay between layers.
• In the latter case, it is obvious that the cumulative number of layers should be
as low as possible to minimize the overall build time for many parts.
POST-PROCESSING

• All AM parts require a degree of post-processing.


• At the low end, this may require removal of support structures or excess powder for
those who merely want quick, simple verification.
• At the high end, the AM process may be a very insignificant time overhead in the
overall process,
• What this generally means to a process planner is compromise. Compromise is not
unusual to a process planner, in fact it is a typical characteristic, but the degree of
flexibility provided by many AM machines makes this a particularly interesting
problem. Just because an AM machine is being used constantly does not mean it is
being used efficiently.
SUMMARY

• It is clear that only process planners who have a very detailed


understanding of all the roles that AM parts can play will be able to
utilize the resources effectively and efficiently. Even then it may be
difficult to perform this task reliably given the large number of
variables involved. A software system to assist in this difficult task
would be a very valuable tool
Thanks

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