Hydra-MMM Prototype
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Release status: unknown
Description | Prototype for multi-headed manufacturing machine
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License | unknown
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Based-on | [[]]
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Contents
Project Background
'Hydra is a multi-headed manufacturing machine that is originally being designed and built for ME463 (senior design) at Purdue University. The general idea is to make a personal manufacturing machine that will be able to perform multiple, simultaneous operations such as milling, additive prototyping, pcb fabrication, laser etching, etc. For the most part, current industrial workplaces have dedicated machines for each one of these functions. By having multiple independent toolheads on the machine, Hydra will be able to perform compound operations that are not possible on dedicated machines (ie FDM rapid prototyping and milling for more accurate part outlines). Hopefully the project will lead to potential discoveries of new manufacturing techniques through the use of compound operations, as well as create a very cost effective product for small business or educational institutions who cannot afford current commercial machines.
Second development stub at (http://objects.reprap.org/wiki/Hydra-MMM_Software_and_Firmware) has been created to handle all details about the software and firmware for the machine.
Please see: http://cpwebste.blogspot.com/ for more information about the build or https://sourceforge.net/projects/hydra-mmm/ for all future software and firmware releases'
Cartesian Robot Target Parameters
What we would like to accomplish with the robot. The goal is to have a very versatile machine that will have superior accuracy and power compared to a belt drive prototyper such as the Mendel, yet still maintain a high maximum printing speed.
500 IPM machining movement, 1000 IPM max speed
XYZ resolution of 2.5 mils (0.0025”)
3 mil (0.003”) max deflection under machining loads
18”x20”x8” build volume
Up to 4 independently controlled toolhead mounts
Concepts
Moving table concept showing multiple Z-axis toolhead mounts
Test axis for determining if leadscrew and sleeve bearing system would perform as desired
Completed Design Analyses
Frame rigidity and table deflection
Guide rail strength and max deflection (used to size all rods)
Machining forces placed on toolhead (milling and drilling)
Sleeve bearing maximum stresses during operation
ACME screw calculations for force, deflection, max rpm, resonance, and resolution
Chopper driver MATLAB circuit analysis (loaded RL circuit with transient and decay)
Several CAD concepts in Pro/Engineer each with a priced BOM for evaluation
Barrel heater viability testing
Thermal model of FDM extruder assembly
Note: if anyone is interested in the actual files behind any of these analyses just let me know
Future Ideas
Build pick-and-place machine
Make attempt at automated prototyping using pick-and-place machine to remove plastic parts once they are done printing. May even try to do some kind of basic manipulation and assembly
Finish pass prototyping: fast FDM prototyping with large diameter nozzle and then use fine milling cutter to refine the layer outlines
Ability to create and recycle plastic material from HDPE (milk cartons)
Heated build platform
Color 3D printing using either multiple extrusion heads with different color filaments or some kind of coloring system to color filament after it has left the nozzle