Eight action rules for the orientation of additive manufacturing parts in powder bed fusion: an industry practice
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ORIGINAL PAPER
Eight action rules for the orientation of additive manufacturing parts in powder bed fusion: an industry practice Christelle Grandvallet1,2 · Mouhamadou Mansour Mbow1 · Trent Mainwaring3 · Franck Pourroy1 · Frédéric Vignat1 · Philippe Marin1 Received: 3 March 2020 / Accepted: 1 August 2020 © Springer-Verlag France SAS, part of Springer Nature 2020
Abstract Additive Manufacturing (AM) requires an important preparation usually conducted in a digital environment. Among the various steps of the AM process, part orientation has a critical impact on the final part quality as many constraints have to be considered by an AM expert. This paper tackles the question of which criteria should be taken into consideration for orienting a part at best. This question is answered from two different sources: scientific literature review and industry practice elicitation As an introduction, AM challenges are presented from a user point of view and shows the need for assisting engineers in their AM activity. It is followed by an appraisal of the state of current research about part orientation and highlights objective criteria for its optimization. It is completed with a case study related to an industry practice in Powder Bed Fusion (PBF) captured by means of a specific knowledge elicitation technique. Thanks to iterations with experts, this knowledge capture has led to the formalization of manufacturing rules associated with orientation criteria. The application of these rules testifies to the quality of parts built and marketed day to day by the company. Finally the output from industry practice and scientific literature are discussed and compared and show significant differences.This outcome can be shared as a best practice between PBF operators and could then constitute a basis for computer-based assistance tool to AM practitioners. Keywords Manufacturing rules · Additive manufacturing · Powder bed fusion · Part orientation · Electron beam melting
1 Introduction 1.1 Additive manufacturing challenges Since a couple of decades, new technologies have been introduced in the manufacturing world, among which, Additive Manufacturing (AM). Their capabilities have then increasingly been drawing the attention of industries as it becomes now possible to build small or medium batches of metallic parts with new shapes, and technical as well as geometrical features. However, this move has entailed changes of practices in industry. Gibson et al. [1]) see many steps in the * Franck Pourroy Franck.Pourroy@grenoble‑inp.fr 1
Univ. Grenoble Alpes, CNRS, Grenoble INP, G-SCOP, 38000 Grenoble, France
2
DP Research Institute, 4, rue des Tropiques, 38130 Echirolles, France
3
Zenith Tecnica, 4/25 Airborne Rd, Rosedale, Auckland 0632, New Zealand
CAD-to-Part lifecycle including the manipulation of STL formats, part removal, clean-up and post-processing. AM can thus be seen as a long process which starts from the design phase (part geometry optimization) up to the quality control of the final part. For instance, CAD can i
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