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Abstract
Solid Ground Curing (SGC) processes are suitable for building multiple parts with different geometry and dimensions in batch production of rapid prototypes; however, problems in model accuracy, quality, and material properties of prototypes limit their applications. This paper describes an investigation of the effects of the SGC processing parameters on dimensional accuracy and mechanical properties. The orthogonal experimental design was used for the experimental study. Four quality characteristics were defined, including x and y dimensional accuracy, impact strength, and elastic modulus of prototypes. Six control factors of processing parameters were identified that have possible effects on the four quality indices. Because of the interactions among the control factors and the limited number of experiments, neural networks were used to establish the relationships between the control factors and the quality characteristics. An optimization was also carried out to determine the processing parameters for quality production of prototypes.
Keywords: Rapid Prototyping, Solid Ground Curing, Experimental Design, Optimization
Introduction
Increasing global competition requires productoriented manufacturing firms to become more flexible and responsive to the ever-changing market. Substantial reduction of product development time will improve firms' response to market demands and therefore gain competitive advantages. Rapid prototyping and manufacturing technologies have been improving manufacturers' responsiveness in several aspects, such as rapid creation of 3D models and prototypes and the cost-effective production of patterns and molds with complex surfaces (Yan and Gu 1996).
Rapid prototyping technologies are capable of directly generating physical objects from CAD models. A variety of rapid prototyping technologies have emerged, including Stereo lithography (SLA), Selective Laser Sintering (SLS), Fused Deposition Manufacturing (FDM), Laminated Object Manufacturing (LOM), Three Dimensional Printing (31) Printing), and Solid Ground Curing (SGC). These technologies have a common feature: the prototype is produced by adding materials, rather than removing or deforming materials as in traditional manufacturing processes (Kruth 1991). These technologies can fill the uncertainty void between the conceptual design and an actual part. The technologies can also significantly improve the efficiency of pattern and mold making processes; however, problems in model accuracy, product quality, and material properties have limited their application.
A significant amount of research has been done in accuracy, quality, and material properties of rapid prototyping processes such as SLA and SLS; however, very little...