Selective Laser Sintering Precision Fixturing for Bearing Joints
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Solution Overview
Problem
Selective laser sintering faces challenges in achieving high precision of shape and surface finish, limiting its suitability for parts requiring firm contact, such as bearing or flange joints, due to lower dimensional precision and surface roughness compared to machining, which increases production costs and reduces throughput.
Innovation Solution
A method involving the preparation of a member with high precision flange portions and a plate with recesses for precise positioning, followed by selective laser sintering of a sintered powder portion on the member, allowing for high precision shaping and subsequent machining of flange portions to achieve the required precision, while the sintered portion provides structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If selective laser sintering is used to form three-dimensionally shaped objects, then production flexibility and complexity handling are improved, but manufacturing precision and surface finish deteriorate
Solution Approach 1:
The product is divided into two distinct parts: a basic three-dimensionally shaped object formed by selective laser sintering and a precision-shaped portion formed by machining. This segmentation allows each part to be produced using the most appropriate method for its specific requirements, resolving the contradiction between production flexibility and manufacturing precision.
Solution Approach 2:
The basic three-dimensionally shaped object is formed in advance by selective laser sintering before the precision machining step. This preliminary action enables the complex geometric shaping to be completed first, followed by precise dimensional adjustments, thereby achieving both production flexibility and manufacturing precision.
2Adaptability or versatility
If selective laser sintering is used to form three-dimensionally shaped objects, then production flexibility is improved, but production time and cost increase due to post-processing machining requirements
Solution Approach 1:
Machining is applied only to specific precision-critical portions of the product rather than the entire object. This local quality approach minimizes the time and cost of post-processing while maintaining production flexibility for complex geometries, thereby improving overall productivity.
Solution Approach 2:
Instead of fully relying on selective laser sintering for the entire product or performing complete machining of all surfaces, the invention applies partial machining only where precision is required. This partial action reduces production time and cost while maintaining the advantages of additive manufacturing for complex shapes.
3Manufacturing precision
If machining is performed after selective laser sintering to correct shape errors, then manufacturing precision is improved, but device complexity and production cost increase due to special jigs and preparations
Solution Approach 1:
The invention introduces a positioning fixture that serves as an intermediary between the selectively laser-sintered object and the machining operation. This fixture simplifies the machining setup by providing automatic positioning and clamping mechanisms, reducing the need for complex special jigs and preparations while maintaining high shape precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of parts with high precision shapes at lower costs by combining selective laser sintering with machining, improving the yield and reducing production time and costs by avoiding post-processing corrections.
Implementation Method 1
a shaping step of forming, by the additive manufacturing apparatus placing a shaping material on the upper surface of the member and irradiating the shaping material with laser light
Implementation Method 2
selective laser sintering is a method of forming a three-dimensionally shaped object by repetitively performing steps of layering raw material powder of, for example, nylon resin, ceramics, or metal and selectively sintering part of a powder layer by irradiating the powder layer with laser light
Data Source
AI summary
A method of producing a product includes a preparation step of preparing a member that constitutes a part of the product, a fixing step of positioning and fixing the member on a plate, a mounting step of positioning and mounting the plate on which the member has been fixed on an additive manufacturing apparatus, a shaping step of forming a shaped portion adhering to the upper surface of the member, a dismounting step of dismounting the plate on which the member bearing the shaped portion formed thereon is fixed from the additive manufacturing apparatus, and a separation step of separating the member bearing the shaped portion formed thereon from the plate.