Layered manufacturing (LM) processes have emerged as legitimate processes for manufacturing various precision microelectronic components and bio-implants. These processes are also being considered for fabricating large customized free forms like buildings, statues, reactor beds, and car bodies. Many of these applications demand high levels of quality (e.g., ) and functional performance. Among the LM processes, extrusion-based processes can potentially offer high production rates together with lower setup and operating costs. Yet process failures resulting from anomalies, such as nozzle clogging, overflow, dynamic instabilities, bambooing, and machine degradation impede a widespread applicability of these processes. Scientific principles that relate the sources of these anomalies to process dynamics seem necessary for effective quality monitoring. In this paper we present a nonlinear lumped-mass model to capture dynamics underlying contour crafting, which is an extrusion-based LM process. The two degrees-of-freedom model, developed based on experimental characterizations, captures salient features of the process dynamics including the prominent manifestations of process nonlinearity. Experimental investigations show that the model can lead to effective monitoring of process conditions including overflow and underflow of material from extrusion nozzle, as well as suboptimal (fast and slow) feed rates of the extrusion head.
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e-mail: satish.t.bukkapatnam@okstate.edu
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February 2007
Technical Papers
Dynamic Modeling and Monitoring of Contour Crafting—An Extrusion-Based Layered Manufacturing Process
Satish Bukkapatnam,
Satish Bukkapatnam
Associate Professor
School of Industrial Engineering and Management,
e-mail: satish.t.bukkapatnam@okstate.edu
Oklahoma State University
, Stillwater, OK
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Ben Clark
Ben Clark
Manufacturing Engineer
Pratt and Whitney Rockeydyne, Inc
, Canoga Park, CA
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Satish Bukkapatnam
Associate Professor
School of Industrial Engineering and Management,
Oklahoma State University
, Stillwater, OKe-mail: satish.t.bukkapatnam@okstate.edu
Ben Clark
Manufacturing Engineer
Pratt and Whitney Rockeydyne, Inc
, Canoga Park, CAJ. Manuf. Sci. Eng. Feb 2007, 129(1): 135-142 (8 pages)
Published Online: August 16, 2006
Article history
Received:
June 6, 2003
Revised:
August 16, 2006
Citation
Bukkapatnam, S., and Clark, B. (August 16, 2006). "Dynamic Modeling and Monitoring of Contour Crafting—An Extrusion-Based Layered Manufacturing Process." ASME. J. Manuf. Sci. Eng. February 2007; 129(1): 135–142. https://doi.org/10.1115/1.2375137
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