FACULTY OF MECHANICAL ENGINEERING

PROPOSAL 1POWDER DELIVERY SYSTEM OF SELECTIVE METAL SINTERING

PREPARED BY: GROUP 11

NAME MATRIC NO

LEE KAR HUAN MH13037LOW MING HUI MH13040SITI KHADIJAH BINTI ABU BAKAR MH13056LEONG GUO BANG MH13063ANG ZHEN CIA MH13065

PROJECT SUPERVISOR: DR. KUMARAN KADIRGAMAMSD LECTURER: DR. MUHAMAD MAT NOOR

MECHANICAL SYSTEM DESIGNBMM 4623

ABSTRACT

This project is to design and develop the powder delivery system. The powder delivery

system is the system that spread metal powder evenly on the sintering platform from the metal

powder reservoir to allow laser to sinter the layer of metal powder. The system basically consists

of four main parts, the metal powder reservoir, sintering platform, roller, and metal powder

collector. The metal powder reservoir is where the metal powder store and ready to feed to the

sintering platform, there is a piston underneath the reservoir to push the metal powder upwards to

allow the roller to spread the metal powder. The sintering platform is where the sintering process

carries out by the laser to form 2D pattern. Once each layer is finished sintered, the platform will

move down a little to allow another layer of metal powder to spread. The stacking of each 2D

layer of metal powder patterns will results a 3D products. The roller is used to spread a thin layer

of metal powder from the reservoir to the sintering platform evenly. Lastly, the metal powder

collector is used to collect the excess powder form the sintering platform.

1.0 INTRODUCTION

Selective Laser Melting (SLM) is an addictive manufacturing (AM) technique which uses

a laser as power source to sinter metal powder to produce 3D parts from 3D modelling. Selective

laser melting is the rapid prototyping technology that used to produced prototype application; it

could even used to produce functional mechanical parts for industrial application. Complex part

could be made with high dimension precision allows manufacturer produce parts that previous

manufacturing process that could not achieve.

1.1 OBJECTIVES

To design the powder delivery system for the Selective Laser Melting (SLM) machine.

To design a stable powder delivery system for Selective Laser Melting (SLM) machine.

To design a powder delivery system to spread thin and uniform layers.

1.2 PROBLEM STATEMENT

The powder delivery system in the Selective Laser Melting plays an important role to the final

product. The function of the powder delivery system is to deliver thin layer of powder to the

sintering platform for the laser to sinter the powder layer by layer to form a 3D model. Each

layer of the metal powder should be delivering in equal quantity and distribute evenly on the

sintering platform or else the product produce will be imperfect. The powder deliver by the

powder delivering system should also be thin enough so that higher precision product could be

made. Another important consideration for the powder delivering system is the vibration. The

sintering platform should be stable enough with minimum vibration to avoid the powder from

scattering.

2.0 LITERATURE REVIEW

The Selective Laser Melting (SLM) starts by metal powder feeding process. The piston from the

reservoir push up a small amount of metal powder, then a roller is used to spread the metal

powder evenly on the sintering platform. The excess powder will push to a metal powder

collector for further usage. The laser is then starts sinter the metal powder according the 3D data.

After the layer is finished sintered, the sintering platform move down a little and allow another

layer of metal powder to spread on the platform. The process is repeated until the product is

finish sintered layer by layer. The metal powder must be spread thin and evenly to ensure each

layer is uniform. The platform must also be stable to ensure the metal powder does not scatter.

3.0 METHODOLOGY

3.1 MATERIALS

a) Perspex sheets

b) Stainless steel tubes

c) Stainless steel plates

d) Stainless steel sheets

e) Fully threaded rods

f) Shaft collars

g) Timing pulleys

h) Bearings

i) Open end timing belts

j) Aluminum beams

k) Linear motion slides

l) Shafts

3.4 ELECTRICAL SYSTEM

a) Arduino Mega

b) Stepper motor

c) Stepper motor driver

3.2 MACHINES

a) CNC lathe machine

b) CNC milling

c) Angle grinder

d) Hand drill

e) EDM machine

f) Arc welding machines

3.3 JOININGS

a) Brackets

b) Bolts

c) Nuts

d) Washers

e) Hot glue gun

f) Epoxy glue

g) Screws

3.4 TOOLS

a) Adjustable spanner

b) Screwdriver

c) Cutter

3.5 Flow ChartSTART

LITERATURE REVIEW

DESIGNING

CONCEPT DESIGNPRESENTATION

MARKET SURVEY AND MATERIAL FINDINGS

RESULT AND DISCUSSION

MATERIAL PREPARATION FOR DESIGN PROTOTYPE

FINAL TESTING ON PROTOTYPE

FINAL PRESENTATION AND SUBMIT REPORT

END

STUDY AND GATHER THE INFORMATION RELATED TO PROJECT

SKETCHING DESIGN AND DESIGN

LIST & GET THE MATERIALS.THEN MAKE AN ANALYSIS OF EACH PART.

ASSEMBLE ALL PART& MAKE A MODIFICATION FOR IMPROVEMENT

DRAFT & TESTING. BOTH MUST COMPLETED &SUBMITTEDWITHIN THE TIME GIVEN.

PRESENT ABOUT THE WHOLE WORK

YES

NO

OBJECTIVE

4.0 MANUAL CALCULATION AND CAD DRAWING

4.1 CAD DRAWING

CAD drawing of powder delivering system (Before render).

CAD drawing of powder delivering system (After render).

Roller

Metal powder reservoir

Sintering platform

Metal powder collector

Stepping Motor

Piston

5.0 DETAIL COST ESTIMATION

ITEMS IMAGESESTIMATED UNIT PRICE

(PER UNIT)QUANTITY TOTAL

PRICE

Stepper motor with

driverRM 80 2 RM 160

Arduino Mega RM 40 1 RM 40

Perspex

sheets RM 6 4 RM 24

Stainless

steel tubes RM 6 1 RM 6

Stainless

steel plates RM 8 2 RM 16

Fully

threaded

rods RM 7 2 RM 14

Shaft

collars RM 5 4 RM 20

Timing

pulleys RM 3 2 RM 6

BearingsRM 10 2 RM 20

Open end

timing

belts

RM 6 4 RM 24

Aluminum

beams

RM 15 4 RM 60

Linear

motion

slidesRM 8 2 RM 16

Shafts

RM 5 4 RM 20

Brackets

RM 2 4 RM 8

Bolts and

nuts

RM 1 10 RM 10

Washers

RM 0.50 10 RM 5

Hot glue

gun

RM 15 1 RM 15

Epoxy

glue

RM 10 1 RM 10

Screws

RM 0.50 10 RM 5

TOTAL ESTIMATED BUDGET (MAXIMUM RM 500) RM 479

6.0 EXPERIMENT PROCEDURE

1) Sketch the powder delivery system.

2) Draw the sketching in CAD software.

3) Fabricate the part according the CAD drawing.

4) Program the Arduino according requirements.

5) Install all the components.

6) Run the software.

7) Observe the functionality of the powder delivery system.

8) Measure the thickness of the powder spread.

7.0 EXPECTED RESULT

The powder delivery system should be working according the coding and design. The powder should be spread evenly on the sintering platform. The powder spread should be thinner than 1 mm thick. The excessive powder should be pushed into the powder container. There should only be minimum leakage of metal powder from the piston of both the metal powder reservoir and the sintering platform.

8.0 CONCLUSION

The powder delivery system should be able to spread the metal powder thin and evenly to the sintering platform to ensure that the quality of the product sintered. The powder delivery system should also with minimum vibration to ensure no scatter of the metal powder.

9.0 REFERENCES

1) Kruth, J.-P., Mercelis, P., Vaerenbergh, J. Van, Froyen, L., & Rombouts, M. (2005). Binding mechanisms in selective laser sintering and selective laser melting. Rapid Prototyping Journal, 11(1), 26–36. doi:10.1108/13552540510573365

2) Kruth, J. P., Froyen, L., Van Vaerenbergh, J., Mercelis, P., Rombouts, M., & Lauwers, B. (2004). Selective laser melting of iron-based powder. In Journal of Materials Processing Technology (Vol. 149, pp. 616–622). doi:10.1016/j.jmatprotec.2003.11.051

3) Yasa, E., Kruth, J. P., & Deckers, J. (2011). Manufacturing by combining Selective Laser Melting and Selective Laser Erosion/laser re-melting. CIRP Annals - Manufacturing Technology, 60(1), 263–266. doi:10.1016/j.cirp.2011.03.063

4) Yasa, E., & Kruth, J. (2011). APPLICATION OF LASER RE-MELTING ON SELECTIVE LASER MELTING PARTS. Advances in Production Engineering & Management, 6(4), 259–270.

5) Yasa, E., & Kruth, J.-P. (2011). Microstructural investigation of Selective Laser Melting 316L stainless steel parts exposed to laser re-melting. Procedia Engineering, 19, 389–395. doi:10.1016/j.proeng.2011.11.130

6) Thijs, L., Verhaeghe, F., Craeghs, T., Humbeeck, J. Van, & Kruth, J. P. (2010). A study of the microstructural evolution during selective laser melting of Ti-6Al-4V. Acta Materialia, 58(9), 3303–3312. doi:10.1016/j.actamat.2010.02.004

7) Kempen, K., Thijs, L., Van Humbeeck, J., & Kruth, J.-P. (2012). Mechanical Properties of AlSi10Mg Produced by Selective Laser Melting. Physics Procedia, 39, 439–446. doi:10.1016/j.phpro.2012.10.059

8) Mumtaz, K. A., Erasenthiran, P., & Hopkinson, N. (2008). High density selective laser melting of Waspaloy?? Journal of Materials Processing Technology, 195(1-3), 77–87. doi:10.1016/j.jmatprotec.2007.04.117

9) Yadroitsev, I., Bertrand, P., & Smurov, I. (2007). Parametric analysis of the selective laser melting process. Applied Surface Science, 253(19), 8064–8069. doi:10.1016/j.apsusc.2007.02.088

10) Meier, H., & Haberland, C. (2008). Experimental studies on selective laser melting of metallic parts. Materialwissenschaft Und Werkstofftechnik, 39(9), 665–670. doi:10.1002/mawe.200800327

11) Kruth, J. P., Mercelis, P., Vaerenbergh, J. Van, Froyen, L., & Rombouts, M. (2005). Binding mechanisms in selective laser sintering and selective laser melting. Rapid Prototyping Journal, 11, 26–36. doi:10.1108/13552540510573365

12) Vandenbroucke, B., & Kruth, J.-P. (2007). Selective laser melting of biocompatible metals for rapid manufacturing of medical parts. Rapid Prototyping Journal, 13(4), 196–203. doi:10.1108/13552540710776142

13) Rombouts, M., Kruth, J. P., Froyen, L., & Mercelis, P. (2006). Fundamentals of selective laser melting of alloyed steel powders. CIRP Annals - Manufacturing Technology, 55(1), 187–192. doi:10.1016/S0007-8506(07)60395-3

14) Shishkovsky, I., Yadroitsev, I., & Smurov, I. (2012). Direct Selective Laser Melting of Nitinol Powder. Physics Procedia, 39, 447–454. doi:10.1016/j.phpro.2012.10.060

15) Gusarov, A. V., Yadroitsev, I., Bertrand, P., & Smurov, I. (2007). Heat transfer modelling and stability analysis of selective laser melting. Applied Surface Science, 254(4), 975–979. doi:10.1016/j.apsusc.2007.08.074

16) Kruth, J., Badrossamay, M., Yasa, E., Deckers, J., Thijs, L., & Humbeeck, J. Van. (2010). Part and material properties in selective laser melting of metals. 16th International Symposium on Electromachining, 1–12.

17) Yadroitsev, I., Thivillon, L., Bertrand, P., & Smurov, I. (2007). Strategy of manufacturing components with designed internal structure by selective laser melting of metallic powder. Applied Surface Science, 254(4), 980–983. doi:10.1016/j.apsusc.2007.08.046

18) Buchbinder, D., Schleifenbaum, H., Heidrich, S., Meiners, W., & Bültmann, J. (2011). High power Selective Laser Melting (HP SLM) of aluminum parts. In Physics Procedia (Vol. 12, pp. 271–278). doi:10.1016/j.phpro.2011.03.035

19) Yadroitsev, I., & Smurov, I. (2011). Surface morphology in selective laser melting of metal powders. In Physics Procedia (Vol. 12, pp. 264–270). doi:10.1016/j.phpro.2011.03.034

20) Aboulkhair, N. T., Everitt, N. M., Ashcroft, I., & Tuck, C. (2014). Reducing porosity in AlSi10Mg parts processed by selective laser melting. Additive Manufacturing, 1, 77–86. doi:10.1016/j.addma.2014.08.001

21) Kumar, S. (2014). Selective Laser Sintering/Melting. In Comprehensive Materials Processing (Vol. 10, pp. 93–134). doi:10.1016/B978-0-08-096532-1.01003-7

22) Yadroitsev, I., Gusarov, A., Yadroitsava, I., & Smurov, I. (2010). Single track formation in selective laser melting of metal powders. Journal of Materials Processing Technology, 210(12), 1624–1631. doi:10.1016/j.jmatprotec.2010.05.010

23) Mercelis, P., & Kruth, J.-P. (2006). Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyping Journal, 12(5), 254–265. doi:10.1108/13552540610707013

24) Chivel, Y. (2013). Optical in-process temperature monitoring of selective laser melting. In Physics Procedia (Vol. 41, pp. 904–910). doi:10.1016/j.phpro.2013.03.165

25) Yasa, E., Deckers, J., & Kruth, J.-P. (2011). The investigation of the influence of laser re-melting on density, surface quality and microstructure of selective laser melting parts. Rapid Prototyping Journal, 17(5), 312–327. doi:10.1108/13552541111156450

10.0 APPENDIX

10.1 PROJECT GANTT CHART

ACTIVITIES W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

PROJECT BRIEFING & GROUP FORMING

PROJECT PROPOSAL & TITLE SELECTION

FIRST IDEA & SELECTIVE PRODUCT

RESEARCH ON MATERIAL NEED TO BE USED

SKECTHING & CAD DRAWING

PURCHASING MATERIALS & TOOLS

ASSEMBLYING PART

TESTING & ANALYSIS

FINAL PRODUCT COMPLETION

REPORT PREPARATION

EXHIBITION

10.2 TEAM ORGANIATION CHART