Transcript
Academia and Additive Manufacturing Engagement with the Maintenance Community Brett P. Conner, PhD Director for Advanced Manufacturing Workforce Initiatives Associate Professor of Mechanical and Industrial Engineering
This material is based on research sponsored by Air Force Research Laboratory under agreement number FA8650-12-2-7230. The US Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon. The views and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of Air Force Research Laboratory or the US Government
BLUF
Four primary ways academia can partner with the DoD Maintenance Community • Research • Collaborative development and demonstration • Partnerships with DoD/Industry • Future workforce
Research •
•
•
• •
New AM processes: faster, improved quality, multi-materials New design tools and methodologies Expanding the fundamental understanding of materials: structure, process, properties, performance New applications enabled by 3D printing Economics of AM
MATURATION OF ADVANCED MANUFACTURING FOR LOW COST SUSTAINMENT (MAMLS) Collaborative development and demonstration •Partnerships with DoD/Industry •Future workforce •
MAMLS •
Tasks • Baseline use of AM by DoD for maintenance and sustainment • Identify and capture best practices • Conduct technology development • Propose and execute technology demonstrations • Create implementation plans
•
•
Customers: ALCs, Operational Level Maintainers, Supply Chain Workforce development outputs
Program Team
Stratasys FDM Composite Tooling
Carbon Fiber Reinforced ULTEM with in plane CTE ~aluminum
Printed trim and drill guide
350 °F, 100 psi Autoclave Cure
Finished access hatch DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220 , 29 April 2016
BAAM Metal Form Tooling
BAAM printed ABS tool coated with UDRIdeveloped hard tool coating 0.125” aluminum sheet formed with 200 tons and produced smooth tool-side finish
(200 ton max, multiple 150 ton) DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220 , 29 April 2016
Youngstown Air Reserve Station (YARS) • 910th Airlift Wing is DoD’s only aerial spray capability and dedicated aerial spray maintenance flight • Missions include: Insect Control, Vegetation control on bombing ranges and Oil spill neutralization • Aircraft: C-130H
Case Study –Yoke Switch Housing Objective: Demonstrate capability for direct rapid production of hard-to-obtain polymer components with supply chain challenges.
Approach: • • •
Scan part with 3D Systems Capture scanner Process scan data with Geomagic Design X Convert to CAD and STL Print with FDM and SLS
Next Steps: • • • •
Coloration (dye) Fit checks Collaboration with AFLCMC In-flight demonstration
$100,000.00 $10,000.00
Cost per part
•
$1,000.00 $100.00 $10.00 $1.00
SLS
DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220 , 29 April 2016
FDM
Injection molding
Injection molding (200 parts)
Complex Joint Case Study •
•
•
Part for a high-demand, low density system System will likely be retired in next five years - maybe Current approach: • Cast two elbow and one T-joint • Traditional patterns and core-boxes
• Cut off flanges on mating surfaces • Weld castings • Inspect welds DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220, 29 April 2016
Contact Dr. Brett Conner Dept. of Mechanical and Industrial Engineering Youngstown State University
[email protected] 330-941-1731
Complex Joint Case Study •
3D sand printing enabled approach: • Redesign – consolidate elbows and T’s into one casting • 3D sand print molds and cores
•
Simplify the fabrication process without investing in tooling
Fully mission capable to the day of retirement Being smart about maintenance
DISTRIBUTION A. Approved for public release: distribution unlimited Case Number: 88ABW-2016-2220, 29 April 2016
Summary •
Four ways academia can partner with the DoD Maintenance Community • • • •
•
•
Research Collaborative development and demonstration Partnerships with DoD/Industry Future workforce
AFRL ManTech and America Makes are facilitating collaboration and partnerships now through MAMLS This approach can be leveraged by DoD, DLA, and the other services
