Rapid Manufacturing Tai ngay!!! Ban co the xoa dong chu nay!!! Springer London Berlin Heidelberg New York Barcelona Hong Kong Milan Paris Singapore Tokyo D T Pham and S.S Dimov Rapid Manufacturing The Technologies and Applications of Rapid Prototyping and Rapid Tooling With 201 Figures , Springer D.T Pham, BE, PhD, DEng, FREng, CEng, FIEE 5.5 Dimov, Dipl Eng, PhD Manufacturing Engineering Centre, School of Engineering, Cardiff University, Cardiff, CF24 OYF British Library Cataloguing in Publication Data Pham, D.T (Duc Truong), 1952Rapid manufacturing: the technologies and applications of rapid prototyping and rapid tooling 1.Design, Industrial 2.Prototypes, Engineering 3.Manufacturing processes 1.Title II.Dimov, S S 658.5'7 ISBN-13: 978-1-4471-1182-5 DOl: 10.1007/978-1-4471-0703-3 e-ISBN-13: 978-1-4471-0703-3 Library of Congress Cataloging-in-Publication Data Pham,D.T Rapid manufacturing: the technologies and applications of rapid proto typing and rapid tooling / D T Pham and S.S Dimov p.cm Includes bibliographical references and index Design, Industrial-Data processing Prototypes, Engineering CAD/CAM systems Manufacturing processes Dimov, S.S., 1959- II Title TSI71.4 P453 2000 658.5'7-dc21 00-063767 Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licences issued by the Copyright Licensing Agency Enquiries concerning reproduction outside those terms should be sent to the publishers © Springer-Verlag London Limited 2001 Softcover reprint of the hardcover 1st edition 2001 The use of registered names, trademarks etc in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant laws and regulations and therefore free for general use Whilst we have made considerable efforts to contact all holders of copyright material contained in this book, we have failed to locate some of them Should holders wish to contact the Publisher, we will be happy to come to some arrangement with them The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made Typesetting: Electronic text files prepared by authors 69/3830-543210 Printed on acid-free paper SPIN 10571891 Preface Rapid manufacturing is a term that embraces rapid prototyping (RP) and rapid tooling (RT) RP is an exciting new technology for quickly creating physical models and functional prototypes directly from CAD models RT generally concerns the production of tooling using inserts RP and RT are means for compressing the time-to-market of products and, as such, are competitiveness enhancing technologies The first five chapters of this book describe the characteristics, capabilities and applications of the main known RP processes Chapter introduces the history ofRP and discusses CAD modelling as a prelude to physical prototyping Chapter provides an overview of different RP techniques including those still under development Chapter examines commercially available RP machines, such as systems for Stereo lithography (SLA), Selective Laser Sintering (SLS), Fused Deposition Modelling (FDM), Solid Ground Curing (SGC), Laser Engineering Net Shaping (LENS) and Laminated Object Manufacturing (LaM) Chapter focuses on a special class of commercial machines, the so-called "concept modellers" mainly to be found in design offices Chapter covers the varied uses of RP as a means for building functional prototypes, patterns for castings, medical models, artworks and test pieces for engineering analysis The next three chapters discuss RT and its applications Indirect methods of producing soft tooling, firm tooling (or bridge tooling) and hard tooling based on RP are described in Chapter 6, while direct methods are dealt with in Chapter Chapter examines the technological capabilities of commercial RT processes from two major suppliers, DTM and EOS The chapter also presents industrial case studies illustrating the use of RT in two key areas, plastics injection moulding and aluminium die-casting vi Rapid Manufacturing The final chapter in the book, Chapter 9, is concerned with process optimisation It reviews the main factors affecting the accuracy of RP parts and the process-specific constraints to be considered when choosing part build orientations The