Hydra-MMM Prototype

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Hydra-MMM Prototype

Release status: unknown

Hydra-MMM logo.jpg
Description
Prototype for multi-headed manufacturing machine
License
unknown
Author
Contributors
Based-on
[[]]
Categories
CAD Models
External Link


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.

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

A second Reprap wiki development page 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.

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 Hydra-MMM moving table concept.png

Test axis for determining if leadscrew and sleeve bearing system would perform as desired Hydra-MMM testaxis.JPG

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