Comparative Studies on Additive and Subtractive Manufacturing in Nigeria Case Study: Helical Gear in a Juice Extractor

Abstract

All over the world, additive and subtractive manufacturing are the two basic manufacturing methods used for the development of engineering goods and products. In most cases, the method adopted by the manufacturers usually depends on its cost-effectiveness. However, most of the manufacturing industries in Nigeria have little or no information on the relative advantages and disadvantages of the two methods. This had led to many industries adopting one particular method hook, line and sinker without considering the merits that would be offered by the alternative manufacturing method. This paper, therefore, compared the two methods of manufacturing by carrying out reverse engineering of worn-out helical gears (components of a juice extractor) developed using additive and subtractive manufacturing techniques. The parts of the equipment were developed using a lathe, milling and deburring machines to carry out the drilling, turning, grinding, milling and deburring for subtractive manufacturing and 3-D printing machine for additive method. Two gears A and B were developed by both subtractive and additive methods using the dimension of two old gears, which serve as the basis for determining the variation of the nomenclatures of the developed gears from the standard. The time used for product development, cost of production and the energy expended during the production of the two gears using additive and subtractive manufacturing methods were also determined using appropriate methods. The study also showed that it is less expensive to produce both gears A and B using the additive method than the subtractive method. Similarly, in term of energy used, less energy was used during fabrication of the gears using additive method than subtractive method but in general, when you want to print a whole component at once the 3D printer volume could be a major constraint. Hence, the adaptation of additive manufacturing method as a whole or part with the existing subtractive method will help to improve manufacturing industries in Nigeria.