Manufacturing readiness assessment and process planning for additive manufacturing

• Κύριος συγγραφέας: Κουτσούκος, Σωτήριος
• Άλλοι συγγραφείς: Σταυρόπουλος, Παναγιώτης
• Μορφή: Thesis
• Γλώσσα: English
• Έκδοση: 2019
• Θέματα: Additive manufacturing; Subtractive manufacturing; Hybrid manufacturing; Manufacturing readiness levels; Process planning; Προσθετική μηχανικοί; Αφαιρετική μηχανική; Υβριδική μηχανική; Επίπεδα ετοιμότητας κατασκευής; Προγραμματισμός διεργασιών

Additive Manufacturing (AM) is still immature in most application areas. Lack of knowledge among potential users is a key barrier for AM uptake. There is therefore a significant need for methods, frameworks and tools that will enable potential users to effectively identify if AM would fit their specific case, select the right AM process for their needs and overall evaluate the Manufacturing Readiness Level, known as MRL, of their product. In this diploma thesis a framework was developed, in order to address that problem, which comprised by five discreet stages, namely MRL 1, MRL 2, MRL 2-3, MRL 3 and MRL 4. MRL 1 regards the identification of manufacturing research opportunities, material properties and manufacturing cost implications. The main goal of MRL 2 is to describe the application field of the product. In this stage the threads of design, materials and process capability and control are evaluated through identification, paper studies and analysis of material and process approaches. In order to proceed to MRL 3 the following three questions need to be answered: (a) “Should we consider AM for this specific product?”, (b) “Can the product be manufactured via AM?”, (c)“If the product cannot be built via AM should we consider Hybrid Manufacturing process (HM)?”. For that reason, MRL 2-3 was developed and three different levels have been constructed in order to address the aforementioned questions. Level 1 regards self-evaluation of different AM technologies, replying to the question of AM being potentially beneficial for a specific use case. Level 2 validates the technical feasibility of AM for a specific part, supporting the user towards deciding the appropriate AM technology type for his specific use case. Both of the above-mentioned levels answer questions (a) and (b) in the form of questionnaires. Level 3 is addressing manufacturability issues, by analyzing the design and proposing manufacturing of certain features with a combination of additive and subtractive manufacturing (SM) where necessary. After the completion of MRL2-3, MRL 3 takes place. The main purpose in this stage is the characterization of manufacturability and producibility, the research of available materials, the identification of target cost and cost-drivers attributes, and the production of a prototype. Finally, in MRL 4, before the practical examination of the prototype begin, potential Key Performance Parameters (KPPs), production simulation methods, cost drivers’ uncertainties and cost mitigation attributes are identified.