Title: Numerical and experimental analysis of product development by composite metal foil manufacturing

Authors: Javaid Butt; Habtom Mebrahtu; Hassan Shirvani

Addresses: Engineering and Built Environment, Anglia Ruskin University, Bishop Hall Lane, CM1 1SQ, Chelmsford, UK ' Engineering and Built Environment, Anglia Ruskin University, Bishop Hall Lane, CM1 1SQ, Chelmsford, UK ' Engineering and Built Environment, Anglia Ruskin University, Bishop Hall Lane, CM1 1SQ, Chelmsford, UK

Abstract: The paper presents a new additive manufacturing process for the production of high quality metal parts and is termed as composite metal foil manufacturing (CMFM). It is a blend of laminated object manufacturing (LOM) and soldering/brazing strategies. A calculated model of a machine in view of the new process has been outlined and its parts accepted for usefulness either by experimentation or recreations. The product development has two stages - the principles of LOM for cutting and stacking of foils and brazing for joining. The process consists of a fibre laser to cut the metal foils, a paste dispenser for depositing the paste, a roller to make the paste of layer between the foils smooth, two thickness sensors to measure the thickness of the part being built and two heated plates to apply heat to the part. In this paper, results of investigations on the sub-processes; laser cutting, final joining and transient thermal analysis are shown.

Keywords: additive manufacturing; LOM; laminated object manufacturing; metal parts; metal foil; laser cutting; brazing; CFD analysis.

DOI: 10.1504/IJRAPIDM.2018.089729

International Journal of Rapid Manufacturing, 2018 Vol.7 No.1, pp.59 - 82

Received: 15 Apr 2017
Accepted: 25 Sep 2017
Published online: 08 Feb 2018 *

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