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ENHANCE STRENGTH, ACCURACY AND PRECISION OF THE 3D PRINTED ASSEMBLY AID GAUGES
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
ENHANCE STRENGTH, ACCURACY AND PRECISION OF THE 3D PRINTED ASSEMBLY AID GAUGES Ramesh Kavalur1, Raghavendra Rao 1 1 Body in White, Manufacturing Engineering, General Motors Technical Centre India Pvt. Ltd, India, Keywords - Additive manufacturing, assembly aid gauges, 3D printer. Research Objective - Automotive manufacturing impressively implementing 3D printed jigs and fixtures. Traditional manufacturing of metal assembly aid gauges have limitations such as lead time and causes dent and rough marks on the outer panel of the body. On the other hand, 3D printed jigs and fixtures, demands more time (depends on complexity), have low level of precision and they offer lower strength. It is observed that this occurs because of the inefficient design and manufacturing without understanding the functionality and capability of the 3D printer. The primary objective of this study is to examine, design & develop 3D printed jigs and fixture to optimize the product, achieve required precision and functionality with improvement in the strength of the product. Methodology - In order to examine, detail examination of existing 3D printed part were studied. After gathering all information about jigs and fixtures, investigation of 3D printed part improvement is proposed. In order to accomplish this work, following important analysis and study was planned. • Design and development of a concept gauge using a 3-dimensional math based model. The common factors considered include, the magnitude and direction of the applied forces, the desired weight and size, requirements for flexibility and the amount of material and time that used in the printing process. • Examination of 3D printing material choice and 3d printer settings to manufacture the part was primary consideration during the design • Once 3D printer capability is studied, model was processed as per desired specification of 3D printing • Evaluated performance of 3D printed gauges and improve the design methodology • Implemented improved process for designing and development of required assembly aid gauges Result - Design and development methodology for 3D printed jigs and fixtures and their realistic manufacturing was achieved through this work. With the help of presented methodology, prerequisite dimensional accuracy with repeatable performance was achieved. This study talks about intelligent design consideration and 3D printing manufacturing which can produce more precise or reliable part, and increases strength of the part. Limitation of the study - • Lead time for gauge manufacturing is more because it is creating layer by layer of thickness 0.01inch. • This study is limited to only FDM 3D printer and the material which 3D printer can print like- Polycarbonate/ABS/Nylon/Ultem material. What does the paper offer that is new in the field including in comparison to other work by the authors? NA Conclusion -Additive manufacturing methodology was proposed and investigated for improvement on design and development of jigs and fixtures. Conceptual jig model with the help of computational analysis was examined. Manufacturing of these gauges with presented methodology demonstrated many advantages in terms of quality, strength, cost and time. 3D printed assembly gauge tool helps to print complex design, easy to handle and reduce lead time. The proposed technique shown a high potential and further investigation on its usage is under investigation.