D3-TIG

Our project goal is to design and build a functioning prototype of the VandalForge V2 3D printer to include: a more user friendly interface, ease of manufacturability, and increase printing capability while maintaining a relatively low manufacturing cost to allow for future retail sale.

Problem Definition
Design and build a functioning prototype of the VandalForge V2 3D printer to include: a more user friendly interface, ease of manufacturability, and increase printing capability while maintaining a relatively low manufacturing cost to allow for future retail sale.

Background
A. Previous Work: 1)Pre-built MIG welder for print head 2)Smoothieboard x5 to control 3d printer motion B. Ways to improve on previous design: 1)More control over weld characteristics: A.Wire-feed and welder power should be independent B.AC and DC welds C. Variable power in frequencies 2)Easier to put together/assemble 3) Modular design, with welder and printer space separate C) Our solution: 1) TIG Welder completely controlled by microcontroller A)TIG vs MIG welders B)TIG welders: separate electrode and wire feed C) MIG welders: the wire (welded material) is the electrode

Solutions
Our Solutions Path TIG welding: [[File:Pictu22222re1.png|400px|thumb|left|Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal. In addition to melting the base metal, a filler material is typically added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that is usually stronger than the base material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld. Welding also requires a form of shield to protect the filler metals or melted metals from being contaminated or oxidized.



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Specifications
Tig, DC/AC, reliable low current, high frequency start

Power/control NEMA17 motors and have I/O

22 in x 30 in x 22 in

12 in x 12 in x 8 in Printhead moves in all 3 axes

Few fasteners, no welding

$2,000

Front door, side window

Camera turns on

Estimated measurement of "stick out"

Design allows later addition of

Convective cooling, with an option to add on liquid cooling later

Detachable components used with 2-bolt anchor

Insulation for weld loop/components is well thought out and implemented

Hole in the top of the enclosure with attachment for ventilation

Semi automated (On/Off only)

Prototype complete/testing before end of fall semester

Smoothieboard
On a typical 3D printer setup, installing a Smoothieboard will mean you do the following things :

Read all of the guide before you start, best way to avoid mistakes Install some Software to talk to your board Install the Windows drivers if using that OS Connect your board via USB and practice talking to it Take a look at the configuration Upgrade your firmware to the latest version if you feel like it Wire your power supply and provide it with power Wire the power supply to Smoothieboard's motor and mosfet power inputs Connect motors to the stepper motor driver outputs Edit your configuration to match your motors Test the motors, and admire your accomplishment for hours Connect Endstops to the endstop inputs Edit your configuration to match your endstops Test your endstops by homing the machine Connect your hotend and heated bed's thermistors to the thermistor inputs Edit your configuration to match your thermistors Test that they read temperature correctly, admire a beautiful temperature graph Connect your hotend and heated bed's heaters to the mosfet outputs Edit your configuration to tell Smoothie what to heat, with what mosfet and how Test that you can correctly control temperature on all heaters, carefully Connect, configure and test any fans you may have Connect, configure and test any probes you may have Setup calibration or leveling if relevant Configure your slicing software and slice a 3D file into a G-code file Use your host software to send your new G-code file to the Smoothieboard Watch as the machine prints using your new Smoothieboard system

Deliverables
Fully functioning prototype of a TFG 3D printer, which is capable of printing steel parts for less than $2,000.

Research
combined

Welding: TIG welding is a welding technology that uses an electric arc to heat/melt an area of the material in question. The arc can then be used to move around the base metal to some extent, or typically a metal rod or wire is added into the melted zone (otherwise known as the puddle) to act as filling material. We learned that TIG uses constant current with variable voltage to keep the electric arc stable.

EE

Control system: The control system of the 3D printer must govern multiple systems. First, it must control the XYZ movement of the printer. Second, it must control the characteristics of the weld by changing the power applied. Third, it must use feedback loops to ensure that the whole system runs smoothly, with as little human intervention as possible. To fill these requirements, we decided to use the Smoothieboard x5, given that the board has enough stepper motor outputs, as well as GPIO pins, to facilitate our system control.

ME

With 3D printing there are multiple well known motion control arrangements. We chose to go with what’s known as a CORE-XY motion system for several reasons. The first reason relates to client requirements, as the project mandates that we use a box style frame. With a box style frame the most efficient use of space for anything but a very small printer is to have the print head, or in our case a TIG nozzle and wire feed system, mobile in both the X and Y directions. To do this there are two common belt setups, one is called Hbot and the other is the aforementioned CORE-XY. While the Hbot is simpler, requiring significantly less belting and fewer pulleys, it applies a torquing force to the XY gantry that we concluded was less desirable than the extra cost and complication of implementing the CORE-XY system. In our design we also have to allow for a very stiff metal print bed that has active cooling to remove the heat from the welding process. In this we decided to have the print bed fixed and thus move the XY motion system in the Z direction as well. In doing this, we realized why every commercial printer, off the shelf kit and home build plans move the bed in the Z direction rather than the the XY system. It’s because moving the the XY system in the vertical is a lot more work. When moving only the bed the only forces that really need consideration are the vertical force of supporting the weight. When moving the XY system the vertical force of the system must be considered as well as dynamic forces on the system of the moving print head.

Lead Instructor and Technical Advisor Meetings
Every week we meet with our lead instructor/client to go over the previous week's project and ask any questions we needed answered.

Every week we had another meeting for just the team, this is where we discussed the project, and made most of our final team decisions.