Re-Engineering of an Impeller for Submersible Electric Pump to Be Produced by Selective Laser Melting

Gennaro Salvatore Ponticelli,Flaviana Tagliaferri,Simone Venettacci,Stefano Guarino,Oliviero Giannini,Matthias Horn

doi:10.3390/app11167375

Gennaro Salvatore Ponticelli, Flaviana Tagliaferri + Show 4 more

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https://doi.org/10.3390/app11167375

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Abstract

The subject of the present study is the reproduction of a submersible electric pump impeller through reverse engineering and additive manufacturing. All of the phases commonly envisaged in the reproduction of an existing piece were carried out. The aim of the study is to show how the chosen pump component can be effectively re-engineered and produced with the selective laser melting technique, obtaining a final product that is comparable if not even better than the starting one. To achieve this goal, the original piece was redesigned and a new model was created and analyzed. The whole process has been split into three main phases: (i) realization of the three-dimensional model from an existing piece using reverse engineering techniques; (ii) finite element analysis for the optimization of the use of the material; and (iii) 3D printing of a concept model in polyethylene terephthalate by using the fused deposition modeling technology and of the functional model in AISI 316 stainless steel with selective laser melting technology.

Highlights

IntroductionTraditional manufacturing processes involve the realization of components through the succession of two phases: an initial phase of coarse forming (by casting, forging, extrusion, rolling, etc.), followed by a final finishing phase (by cutting, turning, milling, drilling, grinding, etc.)
Traditional manufacturing processes involve the realization of components through the succession of two phases: an initial phase of coarse forming, followed by a final finishing phase
The vast majority of objects are still today made using traditional techniques, production based on material removal processes requires auxiliary support systems, often large workspaces, and conspicuous natural and energy resources [8]

Summary

Introduction

Traditional manufacturing processes involve the realization of components through the succession of two phases: an initial phase of coarse forming (by casting, forging, extrusion, rolling, etc.), followed by a final finishing phase (by cutting, turning, milling, drilling, grinding, etc.). Solid parts are created and modeled through subtractive processes of materials [1]. Alongside these well-established traditional processing technologies, the use of unconventional innovative techniques [2], valid in both phases, has become increasingly widespread. These technologies allow one to carry out processes such as cutting, milling, drilling, etc. The push towards the research and industrialization of innovative, unconventional processing technologies is linked to the most important disadvantages of traditional ones [7]. Traditional manufacturing, proves to be little oriented towards environmental, energy, and economic sustainability, leading to the need to research and optimize innovative and more sustainable production processes [9]

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