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Abrasiv nötning av polymerer tillverkade genom 3D-skrivning
University of Skövde, School of Engineering Science.
University of Skövde, School of Engineering Science.
2015 (Swedish)Independent thesis Basic level (university diploma), 15 credits / 22,5 HE creditsStudent thesisAlternative title
Abrasive wear in 3D-printed polymers (English)
Abstract [en]

Volvo Cars in Skövde manufacture and assemble Volvo engines. When attaching the ignition coil to all 4-cylinder engines, a special mounting tool is required. This mounting tool is currently manufactured from injection-molded polyoxymethylene (POM), a thermoplastic. It has been noted that the life span of the tool is shortened as a result of abrasive wear that occurs during the attachment process of the ignition coil.

An investigation of the possibility of manufacturing the mounting tool with a 3D-printer is undertaken in cooperation with ÅF, a consultant to Volvo Cars. A literature study is first presented to introduce broader knowledge on the subject. The abrasive wear and other material characteristics such as tensile strength, compressive strength and elongation of  POM and an alternative material for 3D-printing,  Ultem™, an amorphous thermoplastic polyetherimide are discussed.  These material characteristics are studied further and considered in tandem with both a theoretical analysis and a wear experiment, based on the pin-on-disc method.

It is shown in the theoretical analysis that the wear is approximately six times larger for Ultem™ when compared to POM. The wear resistance of Ultem™ is highest when wear occurs parallel to the direction of the printed layers. In contrast, the experiment shows that the wear is about three times larger in Ultem™ than in POM.  The highest tensile strength of Ultem™ is also found in the direction of the printed layers. Some issues with the small elongation of the 3D-printed material are presented.

It is recommended that ÅF apply the 3D-printing technique with Ultem™ only for construction details with complex geometries and where the material elongation will not exceed 5%. It is also recommended that ÅF both support and contribute to this innovative technique in order to develop leading edge competence in the subject.

Abstract [sv]

Volvo Cars i Skövde tillverkar och monterar Volvomotorer. Vid monteringen av tändspolen till alla 4-cylindriga motorer behövs ett monteringsverktyg. Detta monteringsverktyg tillverkas för närvarande från formsprutad termoplast polyoximetylen (POM). Det har noterats att livslängden av verktyget förkortas på grund av abrasiv nötning som uppkommer under monteringsprocessen av tändspolen.

Möjligheterna att tillverka monteringsverktyget med en 3D-skrivare utvärderas i samverkan med ÅF, en konsult till Volvo Cars. En litteraturstudie presenteras för att introducera en bredare kunskap i ämnet. Den abrasiva nötningen och materialegenskaper såsom draghållfasthet, tryckhållfasthet samt töjning hos POM och ett alternativt material för 3D-skrivning, Ultem™, en amorf termoplast polyeterimid, behandlas. Dessa materialegenskaper studeras vidare och tas i beaktning med både en teoretisk analys och ett nötningsexperiment, baserat på pin-on-disc metoden.

Enligt den teoretiska analysen är nötningen hos Ultem™ approximativt 6 gånger större vid jämförelsen med POM. Nötningsbeständigheten hos Ultem™ är högst då nötning sker parallellt med 3D-skrivningsriktningen av lagren. Nötningsexperimenten visar att nötningen hos Ultem™ är ungefär 3 gånger större vid jämförelsen med POM. Den högsta draghållfastheten hos Ultem™ uppkommer också parallellt med 3D-skrivningsriktningen av lagren. Problem med den låga töjningen hos det 3D-skrivna materialet behandlas.

ÅF rekommenderas att tillämpa 3D-skrivning med materialet Ultem™ främst för detaljer med komplexa geometrier med en töjning som inte överskrider 5 %. ÅF rekommenderas även att både stödja och bidra till denna innovativa teknik för att kunna skapa en ledande expertis i ämnet.

Place, publisher, year, edition, pages
2015. , 60 p.
Keyword [en]
ÅF, Volvo Cars, Volvo, polymer, FDM, Lancaster, TSE, abrasive wear, wear, mechanical engineering, strength of materials, 3D-printing, 3D-printer, polymer
Keyword [sv]
ÅF, Volvo Cars, Volvo, polymer, polymerer, 3D-skrivning, 3D, abrasiv nötning, abrasiv, nötning, maskiningenjör, maskinteknik, material, termoplaster, tribologi, anisotropi, tribometer, jämförelse, nötningsbeständighet, nötningskoefficient, hållfasthet
National Category
Mechanical Engineering Materials Engineering
URN: urn:nbn:se:his:diva-11124OAI: diva2:821904
Subject / course
Mechanical Engineering
Educational program
Mechanical Engineer
2015-05-20, Högskolan, Skövde, 08:56 (Swedish)
Available from: 2015-06-17 Created: 2015-06-15 Last updated: 2015-06-22Bibliographically approved

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