Metal 3D Printing a 48 Blade Turbine Part out of 316L Stainless
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- čas přidán 2. 06. 2024
- Trevor Metal 3D Prints a 48 Blade Part on the TruPrint 2000 from TRUMPF, then uses the ONA EDM to cut the turbine part off the build plate.
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#CNC #Machining #Machinist - Věda a technologie
This type of design and manufacturing is pretty amazing for metal work and it’s application for complex product parts, it’s all just so dope
I did not know EDM existed until 3 weeks ago, when I started a new job. Our shop has 3 of these, but they operate in the open, not under water. Now I see one (for the first time) on CZcams. Amazing idea.
Edm nothing new. Been out for 50 years!
@@codprawn I’ve heard it was used in some form during WW2
@@Guranga93
Probably
Nothing like an electric wire that vaporizes everything in its path with microscopic lightning bolts
Yeah edm is amazing, I've been doing wire eroding and spark erosion (die sinking) for the last 26 years, its old technology but still sometimes its the only way a job can be achieved :)
Love EDM technology and ONA is a leader in developing it. Awesome demonstration of one of the many uses for EDM in any shop.
It's great how you share your process for this complex part.
So satisfying. I just love all the thoughts that go into manufacturing techniques
Looks friggin neat. Could you do some stress tests on a part as thin as that? Also, for a fan I'd imagine the blades would have to be a bit smoother? Are you planning on any other finishing ops?
Maybe you can print to get a smooth finish? I also wonder why there a holes in the fan blades
@@Julian_Bester
Those holes are actually used for heat dispensing. But I doubt this turbine even work.
give us x rays for that beautiful piece
@@prasannajitpadira9655 yeah i really am curious, is this just a fan for looks? or can it actually be put into an aircraft for use?
@@Tay-ky3fi
Pretty sure it can't be used for an aircraft.
Maybe for some industrial turbo fan ?
OMG I wish I could use those machines for my hobbies! I'd have so much fun inventing stuff also! I love this new technology it's freakin' awesome! Please do more stuff like making jet engine turbine blades, turbo wheels, engine blowers, helical miter gears etc., etc.. 👍BOOM!👊
But does this turbine even work? With the very rough surface finish is should induce turbulences.
@@christopherbentley6647 Right, because whales and fans totally operate at the same reynolds numbers.
@@RunesLegacy I put dimples in my forehead with a ball peen hammer so I think faster because #GOLFBALL
I don't think it matters on a high pressure fan like this, I'd say smooth finish matters more on a low pressure fan like a wind turbine.
@@oldchap1228 a un 9 de una noche
Thr biggest problem is the blades balance
This is a game changer I had no idea that this could be done...now if u need a specific part made its just a click away.
I was totally waiting for this
show us "end user product" - perfectly polished and balanced. also what about structural integrity of such production method? right now this looks like extremely wicked peace of scrap metal that will cost a fortune!
Usually the inner porosity is zero on right settings, atleast the centre line core. surface is typically over built for final machining and includes enough meat to account relaxation too.
But it all comes down to the programmers intuition, additive has 100x the variables of subtractive
This is clearly the way to go when reverse engineering machine parts to give an even longer life cycle to any manufacturing process. Amazing proof of concept video!!
AWESOME! Love to see a static and dynamic balance op. Also, real operational temps? Not requiring single crystal high temp blades, obv... Thanks!
Absolutely love it. Amazing how to shorten the Bill of Processes. How long did it took to 3D print the part ? And how long took the wireEDM process ?
That machine is unbelievable 😳
Amazing futuristic technology, you will be leading the market. Thanks Titan
Fascinating to see these cutting edge tech. Thank you for bringing it to us. One question, how the remaining is removed from build plate?
Just incredible what 3d printers are able to do.
Gorgeous piece
Beautiful one. But I wonder if it might need any further heat treatment and surface treatment prior to the operation?
I suspect the multi-operation build with sheet metal provided for smooth surfaces. What processes can be used to improve the surface finish? Is the roughness due to the metal particle size in the 3D laser printer?
request/suggestion if you have time: analysis of material properties, print time, and cost vs the original part. also curious about air or fluid flow over that surface.
All the fancy tec and we still use the trusted G clamp, how long did it take to cut through, Im wire cutting some titanium 3d printed parts and have found the speed is all over the place due to the cavities inside and the way the water blasts ( mines open flush ) but bloody hell 3d prints look good.
3d metal printed,Incredible!
Perfect Gear Wheel,like it~
🎯 Key Takeaways for quick navigation:
01:14 🛠️ Metal 3D printing allows for the creation of complex parts like the 48-blade fan with ease.
03:18 🧰 To prevent the fan from pulling away during cutting, they use a shim and C-clamp to secure it in place.
04:11 ✂️ Additive manufacturing combined with EDM allows for precise cutting of thin-walled parts like this fan.
04:50 📏 The fan features 48 blades, each 50 thou thick, made from 316L stainless steel, resulting in a lightweight and impressive final product.
Made with HARPA AI
That is next level!
im curious about the grain structure of printed parts, can this process be used for high stressed part's that would usually have to be pressed and forged using dyes? would it be able to handle pressures up to 50,000psi, actually forging dyes are quite expensive i could use one of these to print dyes, much easier doing prototyping
Muy hermosa,muy limpia en detalles, pero está balanceada?soporta la fuerza centrífuga? Para que sirve?o es solo demostrativa.
nice, we have a trumpf laser and we love it but our company said we wont buy them again cause customer service is horrible. Is it the same with the 3d printers?
That is awesome!
Was there a rough surface finish as appearance in the video?
Perhaps not as optimal as formed sheet metal blades as regards smooth flow through the fan? Or perhaps secondary operations were done to smooth the blades?
Nice demo.
An excellent application of 3-D printing technology to obtain three-dimensional metal parts that have some complex shape like a turbine part. But it is obvious that the result is only a raw blank of a part that does not have the necessary mechanical properties of the metal (strength, flexibility, fatigue, etc.) and the necessary service characteristics of the working part itself as a whole. Therefore, further development of this technology and, accordingly, obtaining evidence of its effectiveness is necessary.
great idea with the shim. i was scratching my head wondering how you were going to get the cut all the way through.
I wonder if there are way for you to smooth the surface of those blades without crazy multi axis machining. Perhaps tumbling or some sort of vibration based process? Or may be some chemical deposition of some variety?
Also im very curious to see some analytical data comparing the performance, efficiency and other metrics of 3D printed metal part with machined one.
Wondering the same thing. I'm thinking they would put it inside a chamber, and use an abrasive that's sprayed onto the blades by high-pressure nozzles.
Very nice!! How do you remove the remaining material from the table after separating the model?
Oh god, it's nice; I need to see the structure of this print under a microscope.
And I really like to know about printing metal reacts when we polish them.
There are parts you cannot make without seams and gaskets. That's where 3D printing metals really shines... But I am always curious what the real longevity / strength of those parts are.
Yeah, I wondered that as well. How long will that sucker stay together at 20K RPMs or whatever rate the fan is spinning?
The yield strength is comparable (within a few percent) to bulk castings of the same alloys.
@@jdrevenge Care to provide sources for that? Everything I know about materials science leads me to believe that is very much false.
@@smoothbraindetainer Also, that's for ultimate strength, the yield strength of the 3D printed is roughly double, because, well, grain size.
@@jdrevenge Again, sources? You can tell me all you want, but without a reliable resource to back you up it's just warm air to me.
Omg... They wouldn't post it if it wasn't AWESOME!!!
-The stress tests are better than CNC build- guaranteed: Machining creates stress.
+ (remember!)That 3D printer is built for this!!
With all the steps and labor time spent on machining this piece 'old-school' (! Think about it!), I can't believe how anyone is still skeptical about this process being far superior in so many ways.
How close to something like an aerogel can you print? Low density structures in general are pretty interesting depending on the cost.
Nice work. 👍
Very nice print super
Good working so nice 🙂😊
I'd love to see the run out on the lathe
In it's raw state it would be horrible. 3D printing cannot come close to the tolerances of machining.
Cool! What is the print time and cutting time for this piece?
It would have been interesting to have a time lapse timer on screen during the EDM phase. A number of people who have never been exposed to the process may not perceive the actual time committed to each process.
If possible, show us inspecting the finished part balance; which to me; verifies that the print resolution is sufficient to maintain uniformity through out the entire process.
Just for some added dangerous fun and as a durability test: Affix that blade to the previous days spinning top demonstration, spin it up so we can hear it. Maybe add some smoke using a AEROLAB smoke generator for the visuals; similar to devices used in wind tunnel testing. Surely in DFW area, someone would still have them. 😉
EDM is slow. Roug cut on 20-30mm thick steel could be around few mm per minute. Rough cut on 150-200mm will be around 0,5mm per minute and less. Skim cuts (finishing) are faster (up to few mm per minute), but depending on the required tolerance it could require 5 or more skim cuts on very precise features.
@@Stasiek_Zabojca Yep, it's difficult to convey in practical terms that even a child can comprehend. There are many who have no idea that EDM machines have existed for decades or how they affect everyday living.
How would you smooth and polish that? With other manufacturing styles you would have a mirror finish before assembly.
That, is amazing. If that doesn't make you feel blessed, there's something wrong.
I mean, laser cutting is amazing, and even laser cutting isn't ideal to make that kind of part. Even injection molding wouldn't work very well.
If that's just a test piece, kudos to whoever ran it in CAD. The curved blades take time to draw. If that really is a job and not a test piece, it's probably an industrial thing that'll get tumble polished before use. That, is cool. Blows the old days of 3D printing out of the water!
im not sure how smooth or rough the surface finish is but i can imagine that the efficiency of that fan is not what it could be if it was polished or milled.
This is magic!!!
Does the particle size affect final surface finish? Or is it decided by the wattage of the laser beam? Where is the payoff between production cost and surface finish?
Great video. Just would like to know, what's the total hours do you get the final product done, from printing to edm cut?
a day?
Would you guys, or have you already, recreate the Sabu Schist Disc. It's a tri-lobed bowl 61cm in diameter, with a height of 10cm. I'm curious what it sounds like when spinning at different RPM. I am curious if it makes different sounds as different metals, stainless steel, Ti, Brass, Copper, RPM, etc.
Just a curiosity, There are other discs related to it. There's a 5 smaller lobed top disc and another one that's 7, again a topper. I think goes together with the tri-lobed disc. I don't know if it's a propeller, a rope make, musical sound instrument?
The only other way I'd like to get it made is with stone but I don't even know who, how or what for that.
The major problem being the rough surface finish of the blades which would have a big impact on their efficiency I imagine. You would have to add a third process; some kind of polishing tool on a 5 or 7 axis cnc.
Would kinda defeat the purpose, a tumbling machine with some sort of media would probably do a good enough job of polishing it to a smooth enough surface.
Do you think you could make a 4 cylinder, or 8 would be awesome. Or just the top end could easily improve flow.
Is there any way of eliminating the second op? Could a layer of metal powder be laid down on the build plate and then the part built on top of that layer?
What is the total cost of production of the turbine? Can the part have heat treatments to change the properties of the metal in terms of strength and malleability?
How long start to finish. Looks amazing
look nice. but what stress can handle and stufs. i mean when you make stainless still it pass at diferent proces to reduce stres or to induce. How the A.D.M deal with that?
How does printed stainless steal compare to regular in regards to strength?
As an upgrade from my CR10s_Pro and resin printer, do you think I'd be able to fit these two machines in my spare bedroom? ;P
but will the part spin really fast without breaking?
How would you clean the builtplate for a second run?
how strong are printed parts? is at least as strong as cast parts? maybe somewhere in between that and forged ones?
Are the build plates disposable or do the left over supports come off? Face it off?
mindblowing alien technology
I'd be really interested in more info about it as I'm a 3D printing evangelist, teaching about the advantages, this would be a great real-world example. What about a polishing process? Do you have more info about the original part? Time and money savings?
Incredible
Finally something to cool my gaming pc 😎😎
Very nice print, clean and smooth, as much as it can using these methods. And now the 1 million dollars question: what are the printing parameters you have used (LASER power, scan speed, hatching, layer thickness, LASER beam moving strategy, did you use contours?) :P
Most popular 3D machine producer is devolop own parameters. This is big know how
Is the surface textured? I'm curious, a rough surface would not be good for air flow. Can you print with smooth surfaces with this machine? That said, this thing is badass! Thanks for sharing. Also, what was total time to make part and the, total time to cut with EDM?
It's probably not perfectly smooth but good enough
It's a rough texture from the printer, but can be smoothed to a good finish with vapour honing/blasting
Yes, surface is textured. Feels like parts that have been sand blasted or fine to mild grit sandpaper. You would not bolt two flush surfaces of these printed parts together. Mating surfaces are commonly finish machined. 3D printing methods for tubing applications that require smooth-bored channels are commonly Material Jetting (Polyjet) and SLA or DLP.
It would be no trouble to make it smooth
How much time did it take to 3D print it?
WOW 😲 ITS MAGIC
Insane!
Looks like the blades differed in profile and thickness!
good job
What happens to the build plate? Is it actually reusable? How would you clean it up?
Do you use inert gas inside the print chamber?
For those doubting material integrity of the finished part, I wonder why they think 3D parts made with the right additive chemistry and process cannot go through the same heat treatment and finishing processes that a part made with traditional process goes through....
Even if the manufacturing process itself allows levels of strengthening and work hardening, I wonder why people seem to think that it cannot be replicated.
Lots of reputable research suggest it is very much possible and already being done. Is there any reason to believe otherwise?
Because they dont know how traditional process works
Let’s see the parts work in the field then
You can heat treat cast, billet and forged the same way and all will come out differently in strength
I think some Electronic Dance Music as the the background to your Electric Discharge Machining video would have been great! :)
How long does the 3D printing take for a job like that? Is it saving the company a lot more money?
wouldnt you need to perform some sort of heat treatment to remove residual stresses?
What capabilities of the Trumpf TruPrint system made you choose that system over other LPBF systems?
love 3d printing so cool to see how far it has come.... wonder how the durability of the 3d printed part would compare to a cnc part
The durability will be less compared to the cnc
My buddy does plastic printing & each layer is basically a weak spot...
@@tacomonkey222 Actually no, durability is better than CNC. Parts have ~99,99% density and unique small microstructure yields excellent mechanical properties. Strength is below forged but better than CNC.
Surface roughness will have an effect for the fatigue.
@@vn-dc3hv 3D printing doesn't magically add strength to the part. A machined part will be just as strong as a printed part. Assuming the same material is used. In this case 316.
@@brandons9138 it's not magic its metallurgy. Part is built by melting powder with a very small laser, this causes very very rapid melting and cooling which in turn gives very fine and unique grain structure. This microstructure strengthens the metal, especially 316L which you cannot harden by heat treatments. There's really no way to introduce such grain structure into CNC'd part in 316L. Trust me, I did my masters in this exact subject.
Strange, the next recommended video after this is Williams X-jet, a turbine flying booth for 1 person...🤔
Absolutely awesome. I wonder about the strength of the part though.
Very very strong high quality metal. There are plenty of stress test online.
koenigsegg uses 3d printed turbo's
How thick is the material at the centre of the part when you are parting off with wire EDM... Could you not make a internal fixture to hold from front of the part the cut the support material off... Can wire be orientated horizontal with vertical travel
Would save having to stop and clamp, it looked awkward
But I really like your work Guys n girls of Titan
AMAZING CONTENT 🤩
Good job guys. Well done!
I'm curious to know one thing: How do you guys clean the build plate of TruPrint to get it ready for the next workpiece? Cheers from Brazil 🇧🇷
Would like to see it in action respectively the scenarios it's build for.
Top !!! Bravo!!!
I'd like a follow up on this part as from my understanding 3D printed parts don't do so well with fatigue stresses thus I'd like to know how well it did in the field.
Here is how bad they do: czcams.com/video/RrVRSbc6Oec/video.html - porsche printing engine pistons.
"3D printing" is a generic term for many types of additive manufacturing. The process used to make this part could be simplied to say "laser welded". You'll see minor to extreme internal thermal stresses in this manufacturing method. Some parts will have trouble remaining dimensionally stable (depending on the material thickness and part geometry) during thermal reliving. But fatigue failure is not common for this or other types of selective laser melting; However, it is seen in many additive processes that have non-uniform layer density like FDM. The stigma for 3D printing and fatigue failure comes from early 3D printing that was relagated to lactic plastics with little elastic deformation.
Yeah there’s no way it holds up in the field
How do shine it to reduce turblance when spinning please? Thanks
But how strong and balanced are the blades?
Question: To have the best possible airflow, turbine blade surfaces are usually very smooth. Is the rough surface left on these printed blades not an issue then? It would seem to me that it creates turbulence, no? Or is this perhaps just a prototype part and will the production one be made using a different technique? Could someone knowledgeable shed some light on this?
so, instead of a 4 step process you have to:
print it (1 step)
cut it with a wire EDM ( 1.1 step because you have to add the shims )
somehow polish the blades
heat treatment/sintering?
it sounds like it has about the same steps (heavily automated, but steps none the less)
how do they compared in terms of strength and stiffness against the traditional method?
Looks super neat for a low volume run but way too expensive in series production. In my option stamping the blades (high volume) or laser cutting (low-mid vol.) and then laser or resistance welding them together would have been the way to go.
How do you figure that this is too expensive? We don't know the cost.
@@jdrevenge 3d printing 316L like this would cost up to $0.8/gram. So if your part is 1lb then it may cost $362
It looks cool but how is the structural integrity?
From start to finish, what's the cycle time per part?
Judging the comments, I believe most are wondering how realistic this process would be in the production world, compared to the more tedious 4 step process. Thoughts?
I'm curious myself as I've never been in an environment that does actual industrial 3D printing..the kind outside of small fixture and prototyping.
The problem is that a part like this is EXTREMELY hard to make - look at the holes in the blades, which are trivial in additive, brutal in CNC and other processes. Porsche is using a process like that to make the cylinders for high end sports engines - hollow with a support structure, cnc'ing them to tolerances after print. Price IS an issue, but not necessarily for all parts.... and substractive manufacturing has serious limitations in that you need to be able to get the tool into the area to take parts out. Removing powder is more easy.
@@ThomasTomiczek Thank you for your response. It still blows my mind how far the world of 3D printing has come in the last 5 years!
I could see the luxury car brands using this method now that you mention it. Customization is usually prevalent because people buying the exotics can afford it. Makes sense.
@@saram9590 Selective laser melting production applications are for low volume manufacturing on complex geometry parts, and oftern high risk for engineering change. It is also not so new anymore. Enjoy some of my favorite automotive applications from 8 years ago.
czcams.com/video/DNedUZxP8NU/video.html
czcams.com/video/Dw6cs7opvzA/video.html
czcams.com/video/SRA5CFLYkUQ/video.html
What would be the rpm limits on something like this?
I'd like to know
excelente!