RMSelect User Manual
Contents
1. begin the installation process RMSelect User Manual A DOS command window will open and will scroll through the various commands being executed InstalIRMS will create the c Program Files RMSelect folder where the RMSelect executable and associated files will be installed The installer will also create the folder c Program Files MathWorks MATLAB Component Runtime where the MATLAB Component Runtime MCR system will be installed This is a large system 77MB that is required to run MATLAB applications The MCR system need only be installed once any number of RMSelect updates or other MATLAB applications can run on your computer after the MCR system is installed File Edit View Favorites Tools Help da Back Search Lat Folders ca RE LE x A Er Address RMS T RM Select zip F9 970 KE Winzip File S 16f2005 12 25 PM Pe linstallrms bat 1 KE M5 D05 Batch File ef12f2005 2 58 PM ET mcrinstaller zip 77 043 KB WinZip File 3 16 2005 5 19 PM a rmselect ctf 2 043 KB CTF File Sf 16f2005 6 16 AM Select an ikem to view its description Pl rselect exe 26KB Application Bf 16 2005 6 16 AM 7 JRMselection_Manual pdf 280 KB Adobe Acrobat Doc 8 15 2005 5 54 PM See also T RM SelectXML zip 4KB Winzip File 0112120056 4 18 PM My Documents My Network Places M Computer F objectis 156 MB J My Computer Figure 2 1 C RMS Folder after unzipping RMSelect files 4 Some XML data files are required for RMSelect to execute correct2. Fie Database Help icix Choose File gt New Production or File 0pen Project to start Copyright Georgia Tech Dr Dawid Rosen 2005 Figure 3 1 Start up screen with instructions on how to start al x File Database Help New Prototype New Production Open Project Close Project Save Project Exit Copyright Georgia Tech Dr David Rosen 2005 Figure 3 2 File pull down menu with New Production highlighted RMSelect User Manual 3 2 Project Interactions After starting a production project you can enter project and part information then get qualitative and general quantitative assessments of your part with respect to RM machines Start by selecting the Project Data button that is just under the File pull down menu These five buttons lay out the main RMSelect usage procedure When you select the Project Data button you will see a screen similar to that shown in Figure 3 3 As shown you can enter the desired production rate as number of parts per week the target part cost in dollars the estimated duration of the project in weeks estimate how long you will need to manufacture parts at the specified production rate and the estimated service life of the part in years RM Selection loj x File Database Help M Part Data Qualitative Frelim Select Assessment Producton Rate parts week 100 Part Gost target 200 Proect Duration weeks Part Life years C
3. ML Document 7i20 2005 1 Selected O Files 0 bytes Total 4 files 32KB w heal Z Figure 2 2 Extracting the XML files from the RMSelectXML zip archive 3 RM SELECTION USAGE 3 1 Start up Locate the RMSelect icon or RMSelect exe file in the appropriate folder By default RMSelect is intended to be located at c Program Files RMSelect You may have changed this during installation Double click on the RMSelect exe icon to start RMSelect The first time you start RMSelect the system performs a lot of initialization and this takes 20 30 seconds When successfully started you should see a screen similar to the one shown in Figure 3 1 along with a message box stating that you should select one of two entries in the File pull down menu either File gt New Production or File gt Open Project See Figure 3 2 for the File pull down menu If you select File gt New Production the RMSelect system creates a new project for a production manufacturing application RMSelect prompts you for the name of your project After entering the project name you will be able to enter project and part information If you want to open an existing project RMSelect prompts you for a project name using a typical file open dialog box This enables you to select the folder that the project file 1s in as well as the project file RMSelect remembers the folder for future file interactions with the project RMSelect User Manual PRM Selection 215 x
4. RM Selection Software User Manual Version August 12 2005 Dr David Rosen School of Mechanical Engineering Rapid Prototyping amp Manufacturing Institute Georgia Institute of Technology Atlanta GA 30332 0405 404 894 9668 david rosen me gatech edu Copyright 2005 All rights reserved RMSelect User Manual 1 PURPOSE The purpose of the Rapid Manufacturing RM Selection software system 1s to help product developers to evaluate the usage of RM technologies for part manufacture This evaluation can take place early in the product development process since little specific part information 1s needed to use this software Instead general principles are applied general part characteristics in order to perform the evaluation Evaluations take place at two levels First given the project and part characteristics an overall assessment of the suitability of RM as a whole is provided Second general build time part cost and technical feasibility assessments are given for the part to be manufactured by selected commercial RM machines A second purpose of the software is for RM machine developers to explore new machine capabilities for candidate applications For example a new type of ink jet printing technology could be investigated for fabricating small complex custom designed parts Technology characteristics can be entered into the software and manufacturing assessments can be compared between the new printing technology and e
5. ded turnaround times lt may be dificult to achieve imes with conventional manufacturing processes Uniqueness Turnaround Time COM technologies may be the only method for achieving the desired combination of uniqueness and turnaround mes Producton Volume Producton volumes are moderate indicating that COM technologies could be good candidates for manufacturing Figure 3 6 Results of qualitative assessment ck loxi File Database Help M Project Data Part Data Qualitative Prelim Select Assessment Feasible Machines selected SLA S600 SLA 5000 sintersin HiQHs SL4 7000 SLA Wipes Infeasible Machines Sintersin HIGHS Sinter Sin Proi4d SinterSin Praz Copyright Georgia Tech Dr David Rosen 2005 Figure 3 7 Preliminary Selection screen RMSelect User Manual Yat Display OI x File Edit View Insert Tools Desktop Window Help M Part Spacing fim 10 hie 10 Z 10 Number of Parts in Build 4 Part Orientation pez z Update Figure 3 8 Vat and build chamber layout When you are finished selecting machines and possibly viewing their build layouts you can proceed to an approximate quantitative assessment of the selected machines by hitting the Assessment button When you do this RMSelect displays two new windows with assessment results and build time and cost estimates Assessment results for this example are shown in Figure 3 9 Note that RMSelect compares
6. ect Data or Part Data screens to change your entries and repeat the Qualitative assessment to understand how the suitability of RM changes with changes in production or part characteristics RMSelect User Manual RM Selection _ o x Fie Database Help M Project Data Part Data Qualitative Prelim Select Assessment Qualitative Assessment of DOM Suitability For your producton volume how many parts have exacts the same shape Part Consolidaton ls your part replacing more than 1 other part f None all parts have unique shapes f Yes itreplaces an assembly of more than 10 parts C Few lt 10 have exact the same shape Yes itreplaces 6 10 parts Some lt 50 have exactly the same shape Yes itreplaces 2 5 parts All parts have the same shape No the partreplaces 1 other part or this is a unique applicat ee Gomme me How quickhy do you have to resp to design changes or part shape is very complex can fabricate using only DOM Overnight f part shape could be fabricated using Saris mil part shape could be injection molded part could be machined on 2 faxis or Sais mill more than 10 days Copyright Georgia Tech Or David Rosen 2005 Figure 3 5 Qualitative assessment screen When you are finished with qualitative assessment you can proceed to preliminary selection of RM machines by hitting the Prelim Select button This brings you to the screen shown in Figure 3 7 This screen shows
7. ect User Manual Edit AM Machine SLA 540 SLA 6000 SLA 7000 SLA Vippooxx SinterSin HiQHS SinterSin Pro140 SinterSin Pro2S0 Figure 4 3 Edit Machine dialog box 14
8. es such as FDM printing etc Then you can modify the default machine typically an SLA Viper characteristics that represent your new machine RMSelect remembers that you created a new machine type and makes it available for use in the current project or any new projects you work on If you create a new machine class RMSelect remembers that class as well RMSelect overwrites the existing data files containing machine information As a warning there is no undo functionality built into RMSelect at this time so be careful about your changes If you do make a mistake you can always recover the original machine characteristics files from the installation CD or web site RM Selection E ioj x File Database Help E Mew Machine FT Data Qualitative Frelim Select Assessment Mew Material Edit Machine Edit Material Copyright Georgia Tech Dr Dawid Rosen 2005 Figure 4 1 The Machine Database pull down menu 12 RMSelect User Manual New AM Machine 2 i File Edit Tools Window Help New Machine Type Stereolthography v Name SLA Viper Materials polymer Thin Walls True r Build Volume mm x 240 Yf 240 2 240 Multiple Parts N Dimensions 2 r Min Feature Size mm 0 1 Build Time Model Laser Nozzle Bead Dia mm 0 08 Scan Velocity mm sec Min 2000 Max 5000 Jump Velocity mm sec 50000 Hatch Spacing mm O ooo Layer Thickness mm Min 0 05 Num Scan Sets per Layer 2 7 S
9. ly These files are used to define RM machines and default projects for RMSelect The XML files are delivered in one Zip file RMSelectXML zip The installer automatically executes Zip on this file but you must use the Windows extraction wizard Windows XP or a Zip application Windows 2000 see Figure 2 2 to unzip these files When the extraction wizard displays the folder containing XML files simply click on the Extract all files link and ensure that the files are installed in the c Program Files RMSelect folder not a sub folder 5 The next step is the installation of the MCR system The MATLAB Component Runtime wizard appears and aids installing MCR If you see a wizard screen asking if you want to repair or remove MCR click repair and Next The wizard takes a minute or so to extract and install MCR but everything runs automatically from here so no further user interaction is needed except to click Close and terminate the wizard 6 In the command window the installer prompts you to press any key to continue so do so and the installer finishes RMSelect User Manual ell WinZip Evaluation Yersion RMSelectxML zip OI File Actions Options Help eVuEetdseas New Open Favorites Add Extract Encrypt View Checkout Wizard AML Document 6f26 2005 Bio ka LS Machines xml ML Document Fle0 2005 ago ka AM MachinesFiles_ matlab xml SML Document af12 2005 a eta ka SL_ Machines xml
10. machine capabilities to desired part characteristics and determines whether or not a particular machine can meet a specific characteristic If it can then a Y is indicated If not then N is shown For the Sinterstations neither machine can achieve the smooth surface finish specification as indicated by the N s in the Surf Fin column Target values are indicated along the bottom row for convenience Also the cost estimate is shown for each machine The other window shows build time and cost estimates for the machines Since many aspects of machine operation may vary from part to part ranges of time and cost estimates are given Also costs are broken down into operation machine purchase machine maintenance and material costs You can toggle between these cost break downs and minimum and maximum cost estimates using the radio buttons on the left side of the cost graph 10 RMSelect User Manual File Edit View Insert Tools Desktop Window Help M Alternatives Materials Build Vol Surt Fin Tolerance Feature Size Cost SLA Viper w w Y i Y 1982 71 SLA 5000 i y Y Y 1062 06 Sinterstn HiQHS it N y w 1858 71 sinterstn Proi4o iti Y M Y T 261 78 Targets Polymer 3 000 OOO 1 000 YOO OO Figure 3 9 Assessment results ioj File Edit wiew Insert Tools Desktop Window Help M Build Time for Batch hours a00 Color Key Maxim um Estimated s00 J Ww Minimum E Estimated x 400 _
11. opyright Georgia Tech Dr David Rosen 2005 Figure 3 3 Project Data screen After entering project information select the Part Data button to move onto the specification of part related information When you do this you will see a screen like the one in Figure 3 4 In this screen you enter the part size X Y Z bounding box in millimeters the actual part volume in mm the desired material type polymer metal ceramic note that no ceramic machines are available and some part characteristics Enter the smoothest surface finish Ra that has been specified on your part in microns micrometers Also enter the tightest tolerance value that has been specified on your part microns Then enter the smallest feature size either a positive e g rib or negative feature e g hole in millimeters Note that it is OK to enter approximate values that represent general specifications since RMSelect does not reason directly about part build orientation differences in materials or many of the other details required for a careful quantitative assessment RMSelect is intended for use early in product development not when most part details have been determined RMSelect User Manual inix Y File Database Help Project Data Qualitative Prelim Select Assessment Part Size mm x 100 0 Y 100 0 z 100 0 Actual Volume rim Sy 1000000 Material Potym er Smoothest Surface Finish Ra 30 e micron Tighte
12. st Tolerance micron 20 0 smallest Feature Size mm 1 0 Copyright Georgia Tech Dr David Rosen 2005 Figure 3 4 Part Data screen Select the button labeled Qualitative for a qualitative assessment of the likely suitability of RM technologies for the specified project and part information Figure 3 5 shows the screen you will see Answer the four questions as best you can dealing with the shape of parts to be manufactured geometric complexity of the part s the extent to which the part replaces more than one part part consolidation and the turn around time for part orders Based on your answers a qualitative assessment is generated as shown in Figure 3 6 for the answers shown in Figure 3 5 Note that the overall assessment of RM feasibility is given as MUST which indicates that the project and part characteristics indicate a good match for RM capabilities Specifically each part will have a unique shape probably a custom design application and part shape is fairly complex Fast turn around is required for part orders Additionally from an economic viewpoint RM may be favorable since many parts are being consolidated into one In this scenario it is not necessary to invest in hard tooling for these replaced parts and no assembly stations must be utilized to perform part assembly RM may yield considerable cost savings since manufacturing and assembly investments are not needed If desired you can return to the Proj
13. two columns of machines those that seem to be feasible for the specified part characteristics and those that seem infeasible You can select any number of machines from either column for further assessment In addition you can view a layout of the machine vat or build chamber by selecting the green or red Display buttons for a machine in the feasible or infeasible column respectively Four parts can fit in the SLA Viper vat as shown in Figure 3 8 Note that you can modify part orientation as well as the gaps between parts and update the view of the vat or build chamber You can also see how many parts you can fit in one build RMSelect User Manual Production Assessment OI x File Edit View Insert Tools Desktop Window Help M The overall assessment of ODM suitability is Must Important considerations in this assessment include Unique Shape since each part has a unique shape the tasks of tool design fabrication will be lang expensive and tedious Usage of DDM technologies is almost certainly warranted particularly if producton volumes are high Geometric Complexity Geometric complexity is high enough that DOM technologies may provide a good option Part Gonsolidaton Part consolidation should have a major impact on reducing manufacturing costs complexity and life cycle costs through reducton in warehousing of parts tools assembly fixtures etc Turnaround Time DOM technologies should enable the achievement of the nee
14. upports True Max 0 1 Cost Model Machine Price 170000 Annual Maint Cost 17000 Material Cost kg 200 Material Density kg m 3 1 1 Cost of Running Machine s he 18 Personnel Cost hr 25 Useful Life of Machine year H 10 x Best Surface Finish micron 0 8 Min Tolerance micron 2 Purpose s Functional Form Fit Patte Support Height mm 10 Factor for reduced support cross section 70 3 0 3 Pre dip Delay sec 5 Platform Down Movement Time sec 0 Delay between Down and Up Movements sec 0 Platform Up Movement Time sec 0 Z2 Wait sec 15 Material Deposition Time sec 10 Pre Processing Time hr 1 Post Processing Time hr 1 Machine Start up Time hr 0 166666 Number of Machines 1 Save Cancel Figure 4 2 New Machine dialog box To edit a machine description simply select the Edit Machine entry in the Database menu You select the desired machine to edit as shown in Figure 4 3 and make the appropriate changes to entries in a screen similar to Figure 4 2 Hit the Save button to save your changes or Cancel to ignore changes RMSelect will remember your changes after you hit the Save button Again there is no undo functionality in RMSelect Note that the SLA Viper machine is assumed to operate in high resolution mode only for the purposes of RMSelect 13 RMSel
15. xisting commercial machines 2 INSTALLATION There are two ways to obtain RMSelect software through the web or on a CD 2 1 Web based Distribution Go to the URL http www srl gatech edu Members drosen and scroll to the section entitled RMSelect Downloads Two links are there The first is to download the RMSelect user manual you are reading it now The second is for a Zip file containing all RMSelect software It is about 80 MB in size It is best 1f you right click on each link and choose the Save Target As option in the pop up menu This will enable you to save the files to your hard drive You can put the RMSelect software anywhere Subsequent instructions will assume you put it in the c RMS folder Upon installation the RMSelect installer will put RMSelect into specific folders See Section 2 3 for installation instructions 22 CD Distribution Contact David Rosen for a CD with the RMSelect software Upon receiving the CD you will need to copy the files from the CD into a folder on your hard drive Subsequent instructions will assume you put it in the c RMS folder Then follow the installation instructions given in Section 2 3 2 3 Installation Instructions 1 Open the folder c RMS or wherever you installed the RMSelect installation files 2 Unzip the files in the RMSelect zip file After running Zip the c RMS folder should look like the window in Figure 2 1 3 Double click on the installRMS bat file to
16. z200 0 SLA Viper sinterstn HIQHS oL4 5000 sinterstn Prod ee dalle Cost per Part part Cost Elements 2500 Min amp Max 2000 7 GolorKey 1500 _ oe Operation aes o 1000 n SLA Viper sinterstn HIQHS SLA S000 sinterstn Prod Figure 3 10 Build Time and Part Cost graphs 11 RMSelect User Manual If desired you can navigate back to any of the other screens make modifications to the project or part characteristics or select additional machines for assessment 4 MACHINE CHARACTERISTICS RMSelect operates using data files XML format that represent the various machines and their characteristics It is likely that each user will want to tailor the machine characteristics to their own operating practices Furthermore cost characteristics may vary widely between different companies so it is a good idea to edit the machine characteristic data files to reflect your usage and company Under the Database pull down menu you can define a new machine create a new class of machines or edit existing machines New machines and classes of machines are created by selecting the New Machine menu entry as shown in Figure 4 1 When you select this a screen like that shown in Figure 4 2 appears Currently only Stereolithography and Laser Sintering machines are defined in RMSelect You can select either of these and create a new type of SL or LS machine Or you can select Other specify to create a new class of machin
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