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Report of Chess Pieces Reverse Engineering

Autor:   •  August 31, 2017  •  2,627 Words (11 Pages)  •  193 Views

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The technique used here will be Fused Deposition Modeling (FDM). This is because the chess pieces are not very complex in geometry and the size of the model is small enough to process. It is fairly fast to print the small parts. FDM also helps to produce the minimal wastage and ease in removal of support structure. The parts will be looked decent as its surface finish is much better. Rapid prototyping is a well-deserved process for the contribution of the lost chess pieces in the board game.

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PROBLEM STATEMENT

The problems of the lost chess pieces case study has been identified:

- The geometry of the chess pieces is very difficult to be fabricated by using conventional machining processes due to its complex curves at the corner of the part.

- It is cost and time consuming in searching the replacement for each chess piece.

- The computer model of the parts are lost in the CAD system and the CAD model must be retrieved through the use of reverse engineering.

- Based on the constraint of material properties and the shape of the part, the best technique are figured out to improve the mechanical properties of the finished products.

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OBJECTIVES

The objectives of this project are:

- To develop multiple set of cheese pieces

- To determine the most suitable rapid prototyping machines for the development of parts

- Reduce the cost of buying the new chess pieces

CHAPTER 2

METHODOLOGY

2.1 INTRODUCTION

This chapter describes several details of procedures employed for the rapid prototyping in order to achieve the objectives of the project. Before running the prototyping, the method and type of RP needs to be identified. Some modifications were done to suit the objectives and available resources such as the equipment and machine. Figure 2.1 below presents the overall methodology.[pic 2]

[pic 3]

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CREATING CAD MODEL

Model of selected parts were created and subsequently modified in CAD system using solid works. Figures below are shown CAD models of helicopter parts produced in SolidWorks.

[pic 4]

Figure 2. 2: Bishop

[pic 5]

Figure 2. 3: King

[pic 6]

Figure 2. 4: Knight

[pic 7]

Figure 2. 5: Pawn

[pic 8]

Figure 2. 6: Queen

[pic 9]

Figure 2. 7:Rook

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CONVERTING CAD MODEL TO STL FORMAT

By converting the CAD data to STL format. Because the various CAD packages apply a number of different algorithms to represent solid objects, the STL format (Standard Triangulation Language) has been adopted as the standard of the rapid prototyping industry to establish consistency. This STL file is a concrete visualization of the product geometry, built up from triangles. Using triangles to describe a surface, curved surfaces can only be approached. Increasing the number of triangles (i.e., increasing the resolution) yields a better approach. However, it also enlarges the STL file. So, one has to find the optimum balance between file size and part accuracy.

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SLICING THE STL FILE

After converting the CAD file into STL file, it has to insert into the 3D printer softer for analysing the design before production. STL file sliced into thin cross-sectional layers. After the STL file has been sized and oriented, it is sliced in layers with a predefined thickness.

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INSERT THE STL FILE INTO THE RP SOFTWARE

The STL file has to be inserted to the softer to analyse for production.

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GENERATION OF A SUPPORT STRUCTURE

This additional step is not required for all techniques. Because the model is built up in layers, there may be areas that could float away or have overhanging features, which could distort the resulting model. A base and support structures have to be added, which can be easily removed after the building step. Figure below shows Rapid prototyping software to create layers and support.

[pic 10][pic 11]

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PRODUCING THE MODEL USING THE RP MACHINE

To prototype successfully, we have to select an appropriate rapid prototyping tool from existing RP machine in the department of mechanic. First, we have to identify our prototype needs, and then find the tool that most closely meets those needs. Between FDM and 3D printer, the most suitable one for our case was FDM rapid prototyping machine because it is suitable to produce small parts and good mechanical properties.

It is a type of 3D printer with 635 x 660 x 787 mm dimensions which uses the printing principle of Fused Deposition Modelling. Maximum dimensions of printed prototype are 203 x 152 x 152 mm.

This printer prints only one layer of constant thickness 0.254 mm which is as the accuracy of the print in the Z axis very acceptable. This printer used as building material thermoplastic ABC plus Ivory which comes in standardized packages as fibre with a diameter of 1.6 mm rolled onto a reel. Each spool contains 500 cubic centimetres of material.

After starting of print cycle the system warms up printing jet and whole work

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