Overview

Highlights

Course Coordinator:
Dr. K.P.Karunakaran Professor,
Dept of Mech. Engg,
IIT Bombay

Time:
9.30 am to 5.30 pm
April 26 - 30, 2010
(Monday – Friday)

Venue:
Main Guest House,
IIT Bombay

Conformal Cooling Channels

Functionally Gradient Objects

Intricate Shapes

Assembly without Joints

 

Introduction

Customer affluence, product obsolescence and global competition have increased product variety and shortened product life and profit margins. In this scenario, organizational survival, leave alone their success, is solely through shorter time-to-market. Rapid Product Development & Manufacturing (RPD&M) help in shortening product development and manufacturing cycles. RPD&M is the synergic integration of the various time compression technologies for design, evaluation and manufacturing. Time compression is achieved by performing the activities in the virtual world as far as possible. Geometric modeling, Reverse Engineering (RE), Virtual Reality (VR), Finite/Boundary Element Analysis (FEA/BEA), Motion analysis and Virtual Manufacture are some of these tools. When it is no longer possible to proceed virtually, one continues with the activities in the physical world using the fastest tools available. CNC technology, Robotics, Rapid Prototyping (RP), Rapid Tooling (RT) and Rapid Manufacturing (RM) are the physical tools with different levels of time compression. It is important to ensure that all the activities of design, evaluation and manufacturing happen in synergy so that (a) the parallelism existing among the activities is exploited, (b) mistakes are detected and corrected early in the process and (c) the benefits achieved at any stage are carried forward till the end with the least attenuation. The synergic integration is achieved using tools like Concurrent Engineering (CE) and Design for X (DFX), Product Lifecycle Management (PLM) and Enterprise Resource Planning (ERP).

Program Overview

This workshop will begin with an overview to RPD&M. This will be followed by the detailed presentations by the experts from academia and industry on various topics of the three groups of technologies constituting RPD&M. Apart from the basic concepts, these will include demonstrations and case studies as well. The topics that will be covered are:

• Overview to Rapid Product Development

• Geometric Modeling: Wire-frame, surface and solid representations; Various types of solid representations; STL format

• Reverse Engineering (RE): Principle; Legal and ethical issues; Various contact and non-contact methods of capturing a physical object; Construction of the 3D models; Applications and case studies

• Virtual and Augmented Reality (VR): Stereo-vision; tracking-based interaction; Multi-modal perception; Augmented Realit; Applications and case studies

• Finite/Boundary Element Analysis (FEA/BEA): Principle; Applications and case studies

• Rapid Prototyping (RP): Principle; Popular RP processes (Fused Deposition Modeling (FDM), 3D Printing (3DP), Stereo-Lithography Apparatus (SLA) and Selective Laser Sintering (SLS)); Applications/benefits and limitations

• Overview to Rapid Manufacturing: Definition; Roadmap

• Rapid Manufacturing of Non-metallic Objects: Rapid Tooling (RT) processes for quick small volume production (Silicon Rubber Molding, Epoxy Tooling, Spray Metal Tooling etc.)

• Rapid Manufacturing of Metallic Objects: Various direct/indirect and additive/subtractive/hybrid routes (Laminated Manufacturing, powder-bed technologies, deposition technologies, CNC machining, Hybrid technologies and Rapid Casting) and their comparison including the energy source used such as laser, electron beam and electric arc

• Laminated Manufacturing for Metallic Objects: Principle, Issues in the joining of laminates; Case studies

• Powder-bed Technologies for Metallic Objects: Popular and emerging processes (SLS, 3DP and Arcam's Electron Beam Melting (EBM)); Advantages and limitations; Applications and case studies

• Deposition Technologies for Metallic Objects: Comparison of powder-bed and deposition technologies; Popular and emerging processes (Laser Additive Manufacturing (LAM), Laser-Engineered Net Shaping (LENS), Shape Deposition Manufacturing (SDM) and Arc Hybrid Layered Manufacturing (ArcHLM)); Advantages and limitations; Applications and case studies

• Role of High Speed CNC Machining in Rapid Manufacturing: Scientific definition of High Speed Machining (HSM); Enabling technologies (cutting tools, machine tools and CAM packages); Benefits; Applications and case studies

• Rapid Casting: Patternless mold making using additive route (SLS & 3DP); Patternless mold making using subtractive route (ACTech); Sand casting using rapid patterns (FDM, SLS, LOM etc.); Investment casting using rapid patterns (SLS); Segmented Object Manufacturing (SOM)

• Design and Manufacture Using Functionally Gradient Materials

• Applications of Rapid Manufacturing in aerospace, automotive and medicine

• Concurrent Engineering (CE) and Design for X (DFX)

• Product Lifecycle Management (PLM)

Course Coordinator

Dr. K.P. Karunakaran has 25 years of professional experience. He worked in Hindustan Aeronautics Ltd. for 8.5 years in the areas of CNC machining and process planning. He joined the Department of Mechanical Engineering at the Indian Institute of Technology Bombay in 1994. He was a consultant to Mercedes-Benz Technology Centre, Stuttgart (Germany) in Summer 2000 and to VicomTech, San Sebastian (Spain) in Summer 2003. He was a Visiting Professor in the University of Metz in France in Winter 2005 and in Ecole Centrale de Nantes in France in Winters 2006, 2008 & 2009. He has association with Fraunhofer institutes since 1998 through Summer visits (1998, 2002 & 2006) as a Humboldt Fellow.

    He developed OptiLOM, a pre-processor for LOM-RP in collaboration with DaimlerChrysler and Materialise and launched it as a module of Magics during EuroMold 2002. Rapid Manufacturing of metallic objects and optimization of machining through geometric and mechanistic simulation are his research interests. He has developed a GMAW-based Hybrid Layered Manufacturing (HLM) process. Department of IT has funded this research to the tune of Rs. 3 crore. Techno-economic viability of HLM has been established for dies and molds and is ready for commercialization. Economic manufacture of composite injection molds with conformal cooling ducts using discrete adaptive deposition is a unique capability of HLM. HLM is being extended for components using a Hermle C30U 5 axis platform. Dr. Karunakaran has developed Segmented Object Manufacturing (SOM), a new RP process that can make large expanded polystyrene objects. SOM objects can be used as patterns for Lost Foam Casting (LFC). This too is a hybrid process making use of a new slicing concept that enables machining in thick layers. This research is funded by GTRE Bangalore to the tune of Rs. 55 lakhs. 

Faculty

K.P. Karunakaran, IIT Bombay
Vijay P. Bapat, IIT Bombay
S. Suryakumar, IIT Bombay
Nitin Metkar, Huntsman, Mumbai
U. Chandrasekhar, GTRE, Bangalore
Mukesh K Agarwala, 3DPD, Bangalore
Edsel Vaz, Cimatron Technologies Pvt. Ltd., Mumbai
Swapnil Patil, Omira Marketing Ltd., Mumbai

Registration and Course Fee

Interested participants should pre-register at the earliest by sending an email to the coordinator (karuna@iitb.ac.in) along with their designation and contact details. This shall be shortly followed by the formal registration along with the course fee. The number of participants will be limited to 50.

The participation fee is Rs. 18,000 for industries and Rs. 13,500 for academia. The fee will have a discount of 10% if the same organization sends 3 or more delegates. Please add a processing charge of Rs. 100 on outstation cheques.

The course fee in the form of either a bank draft or a cheque drawn in favor of "The Registrar, IIT Bombay - CEP A/c" may be sent to:

Dr. K.P. Karunakaran
Professor
Department of Mechanical Engineering
Indian Institute of Technology Bombay
Powai, Mumbai-400076

The participants will receive a nice course kit that includes a detailed book on Rapid Product Development & Manufacturing compiled by the coordinator. Lunch and refreshments will be provided during the course. Participants must make their own arrangements for travel and stay. A limited number of them can be accommodated in our Guest House on payment.