Kadir KIRAN, Bahri ŞEKERCİ, Kemal Burak URGANCI, Yunus Emre DELİKANLI, Baki GEZGEN

Endüstriyel bir 3 boyutlu yazıcı ile imal edilen ABS malzemeli parçaların boyut hatalarının incelenmesi

Eklemeli imalatta parça boyut hataları temel problemler arasında yerini almaktadır. Cihaz pozisyon hatalarına, parça çekmesine ya da büzülmesine ve STL dosya hatalarına bağlı olarak ortaya çıkan parça boyut hataları üretkenliği olumsuz etkilemektedir. Genel olarak, her bir cihaz-malzeme-imalat parametresi-geometri kombinasyonuna göre parçalarda farklı boyut hataları meydana gelebilmektedir. Dolayısıyla bu hataların hesaplanması ve analiz edilmesi son kullanıcılar ve cihaz imalatçıları açısından büyük önem taşımaktadır. Bu kapsamda adı geçen çalışmada endüstriyel bir üç boyutlu yazıcı olan Zaxe Z1 cihazı ile ABS malzemeli parça imalatında parça boyut hataları araştırılmıştır. İlk olarak, farklı boyutlarda daire, kare ve eşkenar üçgen geometrilerini üzerinde barındıran bir test parçası tasarlanmıştır. Ardından, test parçalarının imalat tablasındaki konumuna göre ortaya çıkan hataları incelemek amacıyla imalat tablasının farklı bölgelerine toplam 5 adet test parçası konumlandırılarak imalatı gerçekleştirilmiştir. Üçüncü adımda, bu test parçaları üzerinde yer alan tüm test geometrileri koordinat ölçme makinesi ile taranarak iki boyutlu profilleri elde edilmiştir. Dördüncü adımda ise, geliştirilen en küçük kareler tabanlı geometri uydurma algoritması ile taranan profillere geometri uydurma yapılmıştır. Son olarak da, uydurulan ve tasarlanan geometriler arasındaki profil toleransı değerleri hesaplanmıştır. Sonuçlar analiz edildiğinde, profil tolerans değerlerinin imalat tablasındaki konuma ve geometriye bağlı olarak değişkenlik sergilediği görülmüştür ve imal edilen tüm geometriler tasarlanan boyutlarından daha küçüktür. Başka bir ifadeyle tüm geometriler çekmeye maruz kalmıştır. Genel olarak bakıldığında, geometri boyutu arttıkça profil tolerans değerlerinde artış söz konusudur. Tüm geometriler için ortalama profil tolerans değeri 0.1987 mm olarak hesaplanmıştır. Bu değerin yarısı, yani ≈+0.1 mm, kadar tarama yollarının kaydırılması ile daha hassas geometriler elde edilebilir.

Anahtar Kelimeler:

Boyut hatası, Eklemeli imalat, Geometri uydurma, Parça çekmesi, Profil toleransı

Investigation of dimensional form errors of parts manufactured with an industrial 3-dimensional printer using ABS material

Part dimensional form errors are among the main problems in additive manufacturing. Part dimensional form errors due to device position errors, part shrinkage, and STL file errors negatively affect productivity. In general, different dimensional form errors may occur in parts according to each device-material-manufacturing parameter-geometry combination. Therefore, the calculation and analysis of these errors is of great importance for end users and device manufacturers. With this scope, in this study, part dimensional form errors were investigated in the manufacturing of parts using ABS material with the Zaxe Z1 device which is an industrial three-dimensional printer. First, a test part accommodating different sizes of circle, square and equilateral triangle geometries was designed. Then, in order to examine the errors that occur according to the position of the test parts on the building platform, a total of 5 test parts were positioned in different regions of the building platform and manufactured. In the third step, all the test geometries on these test parts were scanned with a coordinate measuring machine and their two-dimensional profiles were obtained. In the fourth step, geometry fitting was performed to the scanned profiles with the least squares-based geometry fitting algorithm. Finally, the profile tolerance values between the fitted and designed geometries were calculated. When the results are analyzed, it has been seen that the profile tolerance values vary depending on the location in the building platform and geometry, and all the manufactured geometries are smaller than their designed dimensions. In other words, all the geometries were subjected to shrinkage. Generally speaking, there is an increase in the profile tolerance values as the geometry size increases. The average profile tolerance value for all the geometries was calculated as 0.1987 mm. By offsetting the scanning paths by half of this value, i.e., ≈+0.1 mm, more precise geometries can be obtained.

Keywords:

Dimensional form errors, Additive manufacturing, Geometry fitting, Part shrinkage, Profile tolerance,

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