INSTRUCTION MANUAL
FOR
3-D PRINTING
1GINEERING,
GoLLEGE
GARG
E
KUMAR
SAY
AKGEC
DEPARTMENT OF MECHANICAL ENGINEERING
AJAY KUMAR GARG ENGINEERING COLLEGE
GHAZIABAD
Mr. Ajay Kant Dubey Dr. Pallab Biswas
Workshop Superintendent Prof. & Head, ME, AKGEC
MEP MECHANICALEII|-ISEM
12.STUDY OF3D PRINTING
PRINTING
AIM: STUDY OF 3D
ntino alows for rapid prototyping and onsite manufacturing of products. Initially done
new materials, such as aluminum, bronze and
with plastic.3D printing now uses new techniquies withprinting
Bio-naterials are also being incorporated, such as 3D car cartilage and livcr tissue. As the 3D
otyorows. 3D printing will become a big part of many engineoring ficlds Introduction:- 3D printing allot
of products. Initially done with plastic, 3D printing now
for rapid prototyping and onsite manufacturing and glass. Biomaterials are also being
new techniques with new materials,such as aluminum, bronze,
incormorated. such as 3D printing car cartilage and liver tissue. As the 3D printing industry grows, 3D printing
components of 3D Printer:
willbecome a big part of many engineering fields Cartesian coordinate system. The
.ÁXeS: Fixed Rods The three axes that the 3Dprinter utilizes are on the Movement
linear fixed rods are maintained at right angles to each other, and cach represents a coordinate axis.
type of 3D
The timing belts and pulleys allow the movement of the hot end (or the print bed, depending on the
printer) along each axes according to theg-code (generated by slicing software). The stepper motors power this
movement.
2. Extruder: Extrusion is the feeding of filament into the hot end of the 3D printer. This movement is also
powered by astepper motor. Retraction This mechanism is the puling of the melted filament from the hot end.
This movement is primarily programmed through the g-code to prevent the formation of unwanted filament
creating a bridge between two areas. The bridging of unwanted filament is referred to as stringing or the
formation of cobwebs. Dual Extrusion Some models of 3D printers are equipped with dual extrusion capabilitie
This allows for mixed material objects to be printed. Dual extrusion can used to print outcomplex objects with
different colour material as the support, making it easy to differentiate between the object and the support.
3.Hot End: The hot end is heated to temperatures ranging from 160 Cto 250 C, depending on the type of
filament to be used. The hot end melts the filament and pushes the melted filament through the
end needs to be thermally insulated from the other nozzle. The hot
4. Print Bed: Heated Print beds that are heated improve components of the 3D printer to prevent any damage.
printquality of 3D printed objects. The heated bed is
heated to the glass transition temperature of the filament being used. This
allows the model layers to
melt and stick to the heated bed. Non-Heated Print beds that are not heated require adhesion in the slightly
tape, hairspray, etc. In the innovation lab, painters tape is form of glue,
5. Filament: Filanent is a frequently used for adhesion.
consumable used by 3D printer to print layers. Filament comes in a
materials and colors. Filament can be composedthé of metal, wood, clay, variety of
biomaterials, carbon fiber, etc.
i) ABS: - ABS is a
thermoplastic that needs to be heated to temperatures from 210Cto 250C.ABS cad
only be printed on a 3D printer
it emits a strong unpleasant odor.with
a heated bed, which prevents the
requires a complete enclosure cracking
ABS of the object. When ABS is heate
ii) ii). PLA; - PLA is a while Printing.
220C.PLA is also biodegradablethermoplastic that needs to be heated to
and emits slight odors. PLA is most temperatures from 160C to
PVAPVA is a water soluble plastic that is frequently used for support in frequently used in the all3D printers.
object is left in water where the PVA support is dissolved and the finished
dual extrusion 3D printers. The prmte
remains. object printed in the other filament
Preparíng your 3D Model in
This software is available on our CAD Software: CAD Software is used to create 3D models and
Pro and the industry standard computers and the level of difficulty varies. With the exception of designs
software
computer ,Solidworks main idea is usermentioned, all of these programs are Sketen up
to create drawing directly available on the innovaton la0
in 3D or solid form. From this solid
assemble it directly on their workstation checking clashes and user cat
just drag and drop the solid to drawing block, functionality of it. Creating drawing is pletuy ca
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MEP
MECHANICAL/ II-1SEM
The sequence for creation of an object via additive manufacturing comprises ofa few steps - rigure 1.
3D ÇAD Sliclig nd 3DPdhing Pist-processing Final detail
model formating
Figure 1. Production sequence for a 3D printed object
Preparing your 3D Model for print in ldeamaker software:
These are following step for 3D printing of model
1. Install the 3D print software idea maker
2. Check repair option in this software
3. Set the nozzle parameter and build tack temperature according to the printer guide
Step:-1 Prepare the design Modelsing Designing Software(Solids Work,Autocad etc.)
Step:-2 Convert the designed Model file in Stl ,objformat.
Step:-3 Prepare the design model for printing
Using Software Idea Maker and Ultimaker. Then set all parameter (nozzle temp., build task temp and
support) and also repair your design using software option. Then after generating the file in G-code
format.
Step:-4 ON the 3D Printer and load the filament in nozzle and give the command print by using 3D Printing
Machine.
Extrusion-based 3D printing is the most common technique for 3D printing. Atypical
extrusion-based FDMprinting machine is shown in Figure 2
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MFP
MECHANICAL / II-HSEM
a)
Figure 2. Simple schematic of a 3D printer utilizing an extrusion-based technique
a) Material is fed in the form of cord through an extruder
b) A heater and a nozzle - Deposition head
c) Deposition head fixed on an axis profile with controlled movement by a motor
d) Desired object
e) Desired object is printed on the print bed
) Object printed in the print area - layer by layer due to the cooling of the material and the adhesion
Precaution of 3D Printer machine: These are some following precaution when you print the design in 3D
Printer
1.Mechanical: Do not place limbs inside the build area while the nozzle is in mnotion. The printer nozzle
moves in order to create the object.
2.High Temperature:Do not touch the printer nozzle -it is heated to a high temperature in order to melt
Jthe build material.
3.Always buy replacement parts from the manufacturer for safety related equipment
4.Choose an area that has adequate ventilation and exhaust capability
Safety Equipment:
Safety Glasses Gloves
(rccommended for post processing )
Applications of 3D Printer: Automotive, Medical, Engineering, Customize parts,
Less transport, Freedom for design
Result:
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MECHANICAL/I|-ISEM
13. PATTERN DESIGN AND MAKING
AIM: To Design and Manufacture a Wooden Pattern for a
given
MATERIAL REQUIRED: Teak wood of 50 x 50 x 130 mm3 Casting.
EÌUIPMENT AND TOOLSREQUIRED: Wood Turning Lathe, Vernier
Calipers,Spanner, chuck spanner, and Single PointCutting tool, Emery Paper
Functions of a Pattern:
> A pattern prepares a mold cavity for the purpose of making a casting.
>A pattern may contain projections known as core prints if thecasting
requiresa core and need to be hallow.
Runner, gates and risers (used for introducing and feeding molten metal to
the mold cavity) may form the part of the pattern.
A pattern may help in establishing locating points on the mold and
therefore onthe casting with a purpose to check the casting dimensions.
> Pattern establishes the parting line and parting surfaces in the mold.
Problem:
Design a Pattern for the casting shown in fig. which is to be made of steel by considering
shrinkage and machining allowance. 20
30
40 40 40
ALL DIMEIISIOIIS ARE I MM
Solution:
For Steel Shrinkage Allowance is 2 1lmm/m.
For dimension 40, allowance is 40 x 21/1000
=0.84 ~ 1.0For dimension 30, allowance is
30 x 21/1000 =0.63
ror dimension 20, allowance is 20 x 21/1000 = 0.42
The pattern drawing with required dimensions taking shrinkageinto
account is shown
30.6 in fig.
41 4 4
Machining Allowance:
Assume 2mm allowance on larger diameter size, 1.4mm on 30mm diameter
size and 1.6mmon smaller diameter size.
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Tle pallern drawing with required
dinnensions taking slhrinkage into account is shownMECHANICAL
in fig.
/ I|-ISEM
41
41 41
ALL DIMENSIOUS ARE II MM
PROCEDURE
>The work piece is fixed between live centre and dead center of wood
’Adjust the machine to run the job toa required cutting speed. working lathe.
’Fix the cuting tool in the tool post and make sure that the axis of the job
coin codes with the tip of the cutting tool.
>Give the depth of cut and feed to the cutting tool.
>Plain turning operation is performed until the diameter of the work piece
reduces to43 mm.
>Step turning operation is performed according to the given dimensions.
>Perform shoulder turning operation according to the dimensions shown in fig.
>Frequently check the dimensions by using vernier calipers.
>Finish the work piece using emery paper.
PRECAUTIONS:
>The work piece should be held rigidly between the two centers before
operating the machine.
’Tool should be properly ground, fixed at correct height and properly
secured, and work also be firmly secured. Optimum machining
conditions should bemaintained.
RESULT:
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