Assessment 2 – Design Proposal

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Assessment 2 – Design Proposal (Turnitin Enabled) Due Week 8 (11:30pm, Monday, 2nd
September 2019) – Due
02 September, 2019 11:30 PM
SEM723 – Additive Manufacturing Processes And Applications
Due Week 8 (11:30pm, Monday, 2nd September 2019)
Background
Additive manufacturing (AM) enables the manufacture of parts with complex features that could
not be easily achieved or is impossible to be made via traditional manufacturing processes such as
machining or forming. With AM, more complex shapes can thus be created, both for external
forms and internal structures, leading to improved product performance and reduced weight.
Nevertheless, each category of AM processes has its own limitations. Without the assistance of
support structures and appropriate selection of part build orientations, not all designed structural
features are manufacturable or produced with necessary surface quality.
Assessment Task 2-1 Build orientation and support structure generation (15% of total mark)
In the preceding Assessment Task 1 of Technology Report, you have selected a feasible AM
process appropriate for the manufacture of an engine intake manifold (Figure 1). Prior to its
fabrication, you are required to produce a prototype for design validation using fused deposition
modelling (FDM), a low-cost extrusion-based polymer AM process.
Figure 1 Engine intake manifold (Adapted from GrabCAD)
To achieve this, you need to analyse the CAD model of the intake manifold (provided and
uploaded to the SEM723 Unit Site), determine its build orientation and generate necessary support
for overhang structures. The purpose is to choose an appropriate build orientation for the
fabrication of a high-quality prototype with minimum necessary support structure and post
processing (e.g. support removal, surface sanding & polishing etc.).
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This assessment task requires the use of CAD software and Netfabb additive manufacturing and
design software as well as the UP Studio and UP Mini FDM printer. With approximately 800
words, you are required to draft a report including but not being limited to discussions of:
Overview of the intake manifold structure for manufacturability using FDM
Selection of an appropriate build orientation
Generation and evaluation of necessary support structure
The 3D model with support structure for final FDM printing
Your printed intake manifold prototype using the UP Mini FDM printer
Assessment Task 2-2 Redesign for weight reduction & minimum post processing (20% of total
mark)
After the completion of the prototype for the engine intake manifold, you are now more confident
to take another challenge. One client from a hydraulic manifold manufacturer has approached you
with a request to redesign a small hydraulic manifold block for the purpose of weight reduction.
For your information, a hydraulic manifold is a device that regulates fluid flow between pumps,
actuators and other components in a hydraulic system, and is often operated under high pressures.
With a dimension of 90 mm ´ 60 mm ´ 60 mm (Figure 2; the CAD model has been provided and
uploaded to the SEM723 Unit Site), this hydraulic manifold has a maximum operating pressure of
200 bar. You are required to redesign this hydraulic manifold block for a) weight reduction by at
least 30% without affecting its original functionality and b) determine the build orientation to
reduce the amount of support structure used when printing the part.
Figure 2 Hydraulic manifold block (Adapted from GrabCAD)
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Assessment 2 – Design Proposal (Turnitin Enabled) Due Week 8 (11:30pm,
Monday, 2nd September 2019)
Due 02 September at 11:30 PM Ends 09 September, 2019 11:30 PM
This assessment task requires the use of CAD software and Netfabb additive manufacturing and
design software. With approximately 1200 words, you are required to draft a report outlining the
redesign process of the hydraulic manifold, the AM process flow chart and evidence how it meets
the problem statement requirements. The report will include but not be limited to discussions of:
AM process selection
Redesign process of the hydraulic manifold for weight reduction
Overview of the redesigned hydraulic manifold
Build orientation selection for minimum support structure
The 3D model with support structure
Report Writing
The report should be written in a professional manner including:
Appropriate section headings and document layout
Captions for all figures and tables used
Consistent professional document style (e.g. same size font, bold titles)
Correct use of formal and academic language
The use of spelling checker/grammatical checker
Valid signed/named/dated SEBE Assignment Coversheet
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assignment is the work of the group), except where work quoted or paraphrased is
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been granted by the Unit Chair of this unit. I agree that Deakin University may
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