Ti-6Al-4V alloy is widespread applied in aero-engine components, such as blisk and blades. The surface quality of these components has a remarkable impact on aero-engine in aerodynamic performance and service life. Residual stress and surface roughness are considered as the most representative parameters for evaluating the surface quality. Therefore, in order to analyze the effect of grinding parameters on surface quality and improve the surface quality of components, the grinding parameters, including wheel rotational speed, feed rate, processing depth and abrasive size, were choose, and the influence of each parameter on surface roughness and residual stress were investigated. Besides, the grey relational grade analysis was used to analyze grinding parameters. Finally, through verifying the optimization results, the optimal processing parameters for grinding Ti-6Al-4V alloy were obtained. The results reveals that the surface quality of blade has been improved greatly (73.9% reduce in surface roughness and 26.3% increase in residual stress).
{"title":"Analysis of Grinding Parameters in Machining IBR of Aero-Engine","authors":"T. Zhao, Y. Shi, Z. Q. Zhang, Y. Pu, Z. He","doi":"10.1115/imece2022-89046","DOIUrl":"https://doi.org/10.1115/imece2022-89046","url":null,"abstract":"\u0000 Ti-6Al-4V alloy is widespread applied in aero-engine components, such as blisk and blades. The surface quality of these components has a remarkable impact on aero-engine in aerodynamic performance and service life. Residual stress and surface roughness are considered as the most representative parameters for evaluating the surface quality. Therefore, in order to analyze the effect of grinding parameters on surface quality and improve the surface quality of components, the grinding parameters, including wheel rotational speed, feed rate, processing depth and abrasive size, were choose, and the influence of each parameter on surface roughness and residual stress were investigated. Besides, the grey relational grade analysis was used to analyze grinding parameters. Finally, through verifying the optimization results, the optimal processing parameters for grinding Ti-6Al-4V alloy were obtained. The results reveals that the surface quality of blade has been improved greatly (73.9% reduce in surface roughness and 26.3% increase in residual stress).","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128370245","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ningxiner Zhao, Hongqi Guo, L. Headings, M. Dapino
Previous research has developed a process for producing strong fiber reinforced polymers (FRP)-metal joints via ultrasonic additive manufacturing (UAM), and structural tests have been conducted to characterize the mechanical properties of the joints. In this research, an analytical model and a finite element analysis (FEA) model are developed for UAM-produced FRP-metal joints to provide better joint design and application insights. The analytical model applies both the thick-wall cylindrical pressure vessel theory and Tsai-Wu failure criterion to characterize the stress condition in the embedded fibers and the failure mode when tension is applied to the joint. Comparing the analytical model and experimental results of two different sample configurations, the model is able to predict the peak load of the joint with given material properties and joint geometries. Based on the analytical model, an FEA model is built using LS-DYNA to simulate the tensile testing of FRP-metal joint using shell mesh by homogenizing the hybrid portion of the joint. The stress maps obtained from the FEA model for two joint designs show similar distributions when compared to measured digital image correlation (DIC) strain maps, indicating that the failure modes match the experimental results. The FEA simulation results agree well with the experimental result for peak load and displacement at fracture, with an error of less than 5%.
{"title":"Analytical and Computational Modeling of FRP-Metal Joints Made by Ultrasonic Additive Manufacturing","authors":"Ningxiner Zhao, Hongqi Guo, L. Headings, M. Dapino","doi":"10.1115/imece2022-96827","DOIUrl":"https://doi.org/10.1115/imece2022-96827","url":null,"abstract":"\u0000 Previous research has developed a process for producing strong fiber reinforced polymers (FRP)-metal joints via ultrasonic additive manufacturing (UAM), and structural tests have been conducted to characterize the mechanical properties of the joints. In this research, an analytical model and a finite element analysis (FEA) model are developed for UAM-produced FRP-metal joints to provide better joint design and application insights. The analytical model applies both the thick-wall cylindrical pressure vessel theory and Tsai-Wu failure criterion to characterize the stress condition in the embedded fibers and the failure mode when tension is applied to the joint. Comparing the analytical model and experimental results of two different sample configurations, the model is able to predict the peak load of the joint with given material properties and joint geometries. Based on the analytical model, an FEA model is built using LS-DYNA to simulate the tensile testing of FRP-metal joint using shell mesh by homogenizing the hybrid portion of the joint. The stress maps obtained from the FEA model for two joint designs show similar distributions when compared to measured digital image correlation (DIC) strain maps, indicating that the failure modes match the experimental results. The FEA simulation results agree well with the experimental result for peak load and displacement at fracture, with an error of less than 5%.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"152 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133994700","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Typically, in tube forming, the end cross section is either expanded or reduced, or the tube is bent around a solid mandrel to achieve the desired shape. To reduce the friction generated between the tube and the physical tool like mandrel the tube hydroforming process was developed. The fluid was highly pressurized to expand the tube to a desired shape. The uniform thickness and thus better formability are achieved by replacing mandrel punch with hydraulic pressure in tube hydroforming. If the axial force to deform the tube is dominant in deforming the tube, then the process is termed as hydroforging. In this paper a two-step hydroforging process is discussed. With this two-step process, firstly the tube is bulged using the low fluid pressure and then axial force was applied to deform the tube axially and circumferentially while a constant internal fluid pressure was applied to prevent the buckling. During the first step a ramp pressure is used to provide a maximum bulging without necking, then in the next step a constant same peak ramp pressure or lower is applied while compressing the tube axially. In the previous study, a straight tube was used to study the pressure requirement, bulging, buckling and deformation mechanics to create a disc shape object. In this paper, a taper tube hydroforging was studied. The same two-step process was applied to bulge the tube first and then axially deform the tube. Two tube thicknesses and three angles were studied. The pressure requirement to bulge the tube and deform the tube was investigated. The deformation mechanics was analyzed. In addition, the stress, strain, and thickness distribution were studied and reported.
{"title":"A Numerical Analysis on Taper Tube Hydroforging","authors":"S. Memon, C. Nikhare","doi":"10.1115/imece2022-95536","DOIUrl":"https://doi.org/10.1115/imece2022-95536","url":null,"abstract":"\u0000 Typically, in tube forming, the end cross section is either expanded or reduced, or the tube is bent around a solid mandrel to achieve the desired shape. To reduce the friction generated between the tube and the physical tool like mandrel the tube hydroforming process was developed. The fluid was highly pressurized to expand the tube to a desired shape. The uniform thickness and thus better formability are achieved by replacing mandrel punch with hydraulic pressure in tube hydroforming. If the axial force to deform the tube is dominant in deforming the tube, then the process is termed as hydroforging. In this paper a two-step hydroforging process is discussed. With this two-step process, firstly the tube is bulged using the low fluid pressure and then axial force was applied to deform the tube axially and circumferentially while a constant internal fluid pressure was applied to prevent the buckling. During the first step a ramp pressure is used to provide a maximum bulging without necking, then in the next step a constant same peak ramp pressure or lower is applied while compressing the tube axially. In the previous study, a straight tube was used to study the pressure requirement, bulging, buckling and deformation mechanics to create a disc shape object. In this paper, a taper tube hydroforging was studied. The same two-step process was applied to bulge the tube first and then axially deform the tube. Two tube thicknesses and three angles were studied. The pressure requirement to bulge the tube and deform the tube was investigated. The deformation mechanics was analyzed. In addition, the stress, strain, and thickness distribution were studied and reported.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"46 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127626425","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
K. Billah, M. R. Sarker, Mario Barron Gonzalez, J. Ramírez, Y. Hamidi
In this study, a relatively new and low-cost commodity-type 3D printing filament material, acrylonitrile styrene acrylate (ASA), was used as a feedstock to a commercially available, desktop fused filament fabrication 3D printer. The aim was to correlate the mechanical properties of the 3D printed specimen to the raster orientation and extrusion temperature. Although ASA bears multiple similarities to ABS (acrylonitrile butadiene styrene), its superior UV-resistant properties facilitate a wider adoption in various indoor and outdoor industrial applications. Following ASTM (American Society for Testing and Materials) D 638 standard, ASA specimens were 3D printed at raster orientation angles of 0°/90°, 30°/60°, and +45°/−45° at three different temperatures, namely: 230°C, 250°C, and 270°C. The fabricated specimens were then tensile tested and relevant mechanical properties characterized, including the modulus of elasticity, ultimate tensile stress (UTS), and tensile strain at failure. Overall, ASA material showed promising strength properties for various printing parameters. In addition, the 0°/90° raster orientation was observed to yield the highest mechanical properties, with an average UTS of 34 MPa. The +45°/−45° and 30°/60° specimens showed lower but quite comparable properties with an average UTS of 31 MPa. The results also indicated a strong relationship between the print orientations and the extrusion temperatures. Furthermore, fractured surfaces of the tested specimens were a brittle and craze type of failure on the bulk of the bead. The results of this research may not only aid consumer-level manufacturing endeavors, but also support the industrial-scale manufacturing as well as the numerical modeling community to accurately predict appropriate manufacturing conditions and materials performance.
在这项研究中，一种相对较新的低成本商品型3D打印长丝材料，丙烯腈苯乙烯丙烯酸酯(ASA)，被用作商用台式熔融长丝制造3D打印机的原料。目的是将3D打印样品的机械性能与光栅方向和挤出温度相关联。虽然ASA与ABS(丙烯腈-丁二烯-苯乙烯)有许多相似之处，但其优越的抗紫外线性能有助于在各种室内和室外工业应用中得到更广泛的应用。按照ASTM (American Society for Testing and Materials) D 638标准，在230°C、250°C和270°C三种不同的温度下，以0°/90°、30°/60°和+45°/−45°的光栅方向角对ASA样品进行3D打印。然后对制备的试件进行拉伸测试，并对相关力学性能进行表征，包括弹性模量、极限拉伸应力(UTS)和破坏时的拉伸应变。总的来说，ASA材料在不同的打印参数下表现出良好的强度性能。此外，观察到0°/90°光栅取向产生最高的机械性能，平均UTS为34 MPa。+45°/−45°和30°/60°试样表现出较低但相当相似的性能，平均UTS为31 MPa。结果还表明，打印方向和挤出温度之间有很强的关系。此外，试样的断裂面是脆性和开裂型破坏的大头。这项研究的结果不仅可以帮助消费者水平的制造努力，还可以支持工业规模的制造以及数值建模社区准确预测适当的制造条件和材料性能。
{"title":"Impact of Processing Parameters in Mechanical Properties of the Additively Manufactured Acrylonitrile Styrene Acrylate","authors":"K. Billah, M. R. Sarker, Mario Barron Gonzalez, J. Ramírez, Y. Hamidi","doi":"10.1115/imece2022-95109","DOIUrl":"https://doi.org/10.1115/imece2022-95109","url":null,"abstract":"\u0000 In this study, a relatively new and low-cost commodity-type 3D printing filament material, acrylonitrile styrene acrylate (ASA), was used as a feedstock to a commercially available, desktop fused filament fabrication 3D printer. The aim was to correlate the mechanical properties of the 3D printed specimen to the raster orientation and extrusion temperature. Although ASA bears multiple similarities to ABS (acrylonitrile butadiene styrene), its superior UV-resistant properties facilitate a wider adoption in various indoor and outdoor industrial applications. Following ASTM (American Society for Testing and Materials) D 638 standard, ASA specimens were 3D printed at raster orientation angles of 0°/90°, 30°/60°, and +45°/−45° at three different temperatures, namely: 230°C, 250°C, and 270°C. The fabricated specimens were then tensile tested and relevant mechanical properties characterized, including the modulus of elasticity, ultimate tensile stress (UTS), and tensile strain at failure. Overall, ASA material showed promising strength properties for various printing parameters. In addition, the 0°/90° raster orientation was observed to yield the highest mechanical properties, with an average UTS of 34 MPa. The +45°/−45° and 30°/60° specimens showed lower but quite comparable properties with an average UTS of 31 MPa. The results also indicated a strong relationship between the print orientations and the extrusion temperatures. Furthermore, fractured surfaces of the tested specimens were a brittle and craze type of failure on the bulk of the bead. The results of this research may not only aid consumer-level manufacturing endeavors, but also support the industrial-scale manufacturing as well as the numerical modeling community to accurately predict appropriate manufacturing conditions and materials performance.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"20 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128504950","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Electron beam melting (EBM) is a powder bed fusion process capable of manufacturing metallic components out of a variety of alloys. The process is unique in that it relies on the generation of a uniform, densely packed powder bed under vacuum conditions at high temperatures. Therefore, understanding the behavior of the powder subjected to the build environment is crucial to developing the process further. This study presents a method for comparing the flowability, angle of repose, and packing arrangements of non-virgin Ti-6Al-4V powder under atmospheric and vacuum conditions. The two-dimensional particle packing behavior was acquired during the filling of a container constructed from microscope slides and double-sided adhesive. Data on the Newton or “kissing” number was then analyzed using optical microscopy. To facilitate identical measurements within a vacuum environment, a device was designed to initiate flow within a vacuum chamber using a photoresistor switch and “mechanical finger”. The results show that vacuum environments have negligible effect on powder behavior. These results are important in understanding the connections between benchtop measurements and how they correlate to powder performance within the build chamber. While not explicitly tested, the potential effects that temperature has on powder flow performance will also be discussed.
{"title":"Particle Flow and Packing Behavior of Electron Beam Melting Ti-6Al-4V Powder Under Atmospheric and Vacuum Conditions","authors":"Garrett M. Kelley, Ramulu Mamidala","doi":"10.1115/imece2022-96806","DOIUrl":"https://doi.org/10.1115/imece2022-96806","url":null,"abstract":"\u0000 Electron beam melting (EBM) is a powder bed fusion process capable of manufacturing metallic components out of a variety of alloys. The process is unique in that it relies on the generation of a uniform, densely packed powder bed under vacuum conditions at high temperatures. Therefore, understanding the behavior of the powder subjected to the build environment is crucial to developing the process further.\u0000 This study presents a method for comparing the flowability, angle of repose, and packing arrangements of non-virgin Ti-6Al-4V powder under atmospheric and vacuum conditions. The two-dimensional particle packing behavior was acquired during the filling of a container constructed from microscope slides and double-sided adhesive. Data on the Newton or “kissing” number was then analyzed using optical microscopy. To facilitate identical measurements within a vacuum environment, a device was designed to initiate flow within a vacuum chamber using a photoresistor switch and “mechanical finger”. The results show that vacuum environments have negligible effect on powder behavior. These results are important in understanding the connections between benchtop measurements and how they correlate to powder performance within the build chamber. While not explicitly tested, the potential effects that temperature has on powder flow performance will also be discussed.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"8 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125373496","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Joshua Foster, S. Kumpaty, Liam Coen, Al Perkins, Michael Gengler, Scott Woida
Midwest Engineered Systems Inc. has created a novel laser wire metal deposition process, ADDere manufacturing. ADDere has a much higher deposition rate than powder bed fusion, making it ideal for large components. In this project, the mechanical properties of ADDere printed materials were tested and compared to typical values found in ASM publications to show the quality of materials manufactured by the ADDere printing process. A detailed material analysis was performed on samples made from Ti-6Al-4V and 17-4 PH stainless steel. This work builds upon an earlier study of samples made from 17-4 PH that were produced using a single direction pattern. In this project, the 17-4 PH samples were printed in a cross hatched pattern, and testing results were compared to existing data from single direction samples of the previous research. The Ti-6Al-4V samples were created in two builds. One using the unidirectional method and the other with the crossed pattern. Testing specimens were removed from the samples using a water jet cutter and further machined into ASTM tensile bars and metallurgic mounts to perform a thorough material evaluation. The Ti-6Al-4V sample met the expected values in the ASM literature, and the cross hatched 17-4 PH exhibited a higher hardness and better microstructure than the single direction samples from the previous work. It was also observed that when the Ti64 samples were manufactured in the cross hatched pattern, the properties indicated slight improvement and more homogeneity than those printed in single layer direction. The obtained results indicate that ADDere’s printing process can produce highly refined materials that are customizable with their expected uses. This work showcases an excellent industry collaboration of an undergraduate research experience.
{"title":"Characterization of Additively Manufactured Metals from ADDere Printing","authors":"Joshua Foster, S. Kumpaty, Liam Coen, Al Perkins, Michael Gengler, Scott Woida","doi":"10.1115/imece2022-88299","DOIUrl":"https://doi.org/10.1115/imece2022-88299","url":null,"abstract":"\u0000 Midwest Engineered Systems Inc. has created a novel laser wire metal deposition process, ADDere manufacturing. ADDere has a much higher deposition rate than powder bed fusion, making it ideal for large components. In this project, the mechanical properties of ADDere printed materials were tested and compared to typical values found in ASM publications to show the quality of materials manufactured by the ADDere printing process. A detailed material analysis was performed on samples made from Ti-6Al-4V and 17-4 PH stainless steel. This work builds upon an earlier study of samples made from 17-4 PH that were produced using a single direction pattern. In this project, the 17-4 PH samples were printed in a cross hatched pattern, and testing results were compared to existing data from single direction samples of the previous research. The Ti-6Al-4V samples were created in two builds. One using the unidirectional method and the other with the crossed pattern. Testing specimens were removed from the samples using a water jet cutter and further machined into ASTM tensile bars and metallurgic mounts to perform a thorough material evaluation. The Ti-6Al-4V sample met the expected values in the ASM literature, and the cross hatched 17-4 PH exhibited a higher hardness and better microstructure than the single direction samples from the previous work. It was also observed that when the Ti64 samples were manufactured in the cross hatched pattern, the properties indicated slight improvement and more homogeneity than those printed in single layer direction. The obtained results indicate that ADDere’s printing process can produce highly refined materials that are customizable with their expected uses. This work showcases an excellent industry collaboration of an undergraduate research experience.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"69 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122561236","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Martin Roth, Markus Johannes Seitz, B. Schleich, S. Wartzack
Optimization has gained increased attention in product development and is nowadays profitably used to solve complex design problems. In tolerance design, tolerance-cost optimization is a systematic and efficient approach to allocate part tolerance values in a cost-optimal way. The usage of sampling-based tolerance analysis techniques thereby enables the consideration of machine-specific part tolerance distributions as well as individual batch sizes and thus facilitates a concurrent allocation of tolerances and machines. With the aim to further exploit its potential by embedding assembly aspects, this article presents a novel approach combining tolerance-cost optimization and optimal selective assembly. Based on an initial introduction of its general idea, a global optimization problem is defined to simultaneously identify the best combination of tolerance values, machines with their batch sizes and sorting orders of the individual batches. Subsequently, its solution using metaheuristic optimization algorithms and mixed-integer variables is presented. The theoretical findings are finally confirmed by its exemplary application to a use case indicating that it can reveal hidden cost improvement potentials in tolerance design.
{"title":"Coupling Sampling-Based Tolerance-Cost Optimization and Selective Assembly – An Integrated Approach for Optimal Tolerance Allocation","authors":"Martin Roth, Markus Johannes Seitz, B. Schleich, S. Wartzack","doi":"10.1115/imece2022-88775","DOIUrl":"https://doi.org/10.1115/imece2022-88775","url":null,"abstract":"\u0000 Optimization has gained increased attention in product development and is nowadays profitably used to solve complex design problems. In tolerance design, tolerance-cost optimization is a systematic and efficient approach to allocate part tolerance values in a cost-optimal way. The usage of sampling-based tolerance analysis techniques thereby enables the consideration of machine-specific part tolerance distributions as well as individual batch sizes and thus facilitates a concurrent allocation of tolerances and machines. With the aim to further exploit its potential by embedding assembly aspects, this article presents a novel approach combining tolerance-cost optimization and optimal selective assembly. Based on an initial introduction of its general idea, a global optimization problem is defined to simultaneously identify the best combination of tolerance values, machines with their batch sizes and sorting orders of the individual batches. Subsequently, its solution using metaheuristic optimization algorithms and mixed-integer variables is presented. The theoretical findings are finally confirmed by its exemplary application to a use case indicating that it can reveal hidden cost improvement potentials in tolerance design.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114060980","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ahmad Hisham, Shafahat Ali, S. Abdallah, Abdalla Mohammed, R. Susantyoko, S. Pervaiz
The development of advanced composite materials in the recent years has changed numerous aspects of the manufacturing sector. These advanced composite materials showed the potential to replace high-performance alloys at extremely competitive costs. Additive manufacturing gained popularity in the industry due to the ability to print complex shapes. As per existing literature cellular geometry has a controlling influence on the mechanical behavior, and it can be employed to have tunable mechanical properties. Onyx™ is a composite material comprised of nylon mixed with chopped micro-carbon-fiber. For this study, 3D printed nylon-carbon fiber reinforced composite specimens were fabricated using a high-end Markforged® X7™ printer. The study aimed to experimentally investigate the Young’s modulus, ultimate tensile strength, and toughness of the 3D printed nylon-carbon fiber composites having cellular geometry structure. The study investigated different cellular geometry patterns, strain rates and layer heights. Taguchi assisted design of experiment was utilized. To reach reasonable conclusion, a multi objective optimization technique known as grey relational analysis was utilized. Parameters should be optimized in to have proper melting of filament and material solidification. It was found that the optimal parametric condition was diamond horizontal infill pattern, strain rate of 1 mm/ min and a layer height of 0.1 mm. It was observed that sensitivity of 3D printed cellular materials significantly controls the quality of the specimens.
{"title":"Experimental and Statistical Optimization of Carbon-Fiber Reinforced Nylon Composite Based 3D Printed Cellular Structures","authors":"Ahmad Hisham, Shafahat Ali, S. Abdallah, Abdalla Mohammed, R. Susantyoko, S. Pervaiz","doi":"10.1115/imece2022-95727","DOIUrl":"https://doi.org/10.1115/imece2022-95727","url":null,"abstract":"\u0000 The development of advanced composite materials in the recent years has changed numerous aspects of the manufacturing sector. These advanced composite materials showed the potential to replace high-performance alloys at extremely competitive costs. Additive manufacturing gained popularity in the industry due to the ability to print complex shapes. As per existing literature cellular geometry has a controlling influence on the mechanical behavior, and it can be employed to have tunable mechanical properties. Onyx™ is a composite material comprised of nylon mixed with chopped micro-carbon-fiber. For this study, 3D printed nylon-carbon fiber reinforced composite specimens were fabricated using a high-end Markforged® X7™ printer. The study aimed to experimentally investigate the Young’s modulus, ultimate tensile strength, and toughness of the 3D printed nylon-carbon fiber composites having cellular geometry structure. The study investigated different cellular geometry patterns, strain rates and layer heights. Taguchi assisted design of experiment was utilized. To reach reasonable conclusion, a multi objective optimization technique known as grey relational analysis was utilized. Parameters should be optimized in to have proper melting of filament and material solidification. It was found that the optimal parametric condition was diamond horizontal infill pattern, strain rate of 1 mm/ min and a layer height of 0.1 mm. It was observed that sensitivity of 3D printed cellular materials significantly controls the quality of the specimens.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"120967094","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
W. J. Emblom, Christopher Foreman, Charles Kreamer, Sydney E. Frazier, Seth Doiga, Michael Leaumont, Ayotunde Olayinka, P. Darby, Scott W. Wagner
Friction stir processing is being used to improve characteristics of advanced manufactured process by improving the strength and ductility of material, joining, surface characteristics, and alloying. In addition, friction stir processing may be used as a first step for recycling metallic waste. The authors are interested in the friction stir processing because they see that friction stir extrusion may be used for producing unique components that could be useful for the development of fuel cells, micromanufacturing, heat exchangers, biomedical applications, and MEMS. The goal of the current project is to develop a custom built friction stir machine in order to investigate multi-scale friction stir extrusion processes. The machine will be used to characterize various friction stir extrusion processes such as forward and backwards extrusion to produce solid cylinders and tubes with outside diameters up to 37-mm down to 3-mm and for tubes with internal diameters down to 2-mm. In addition, various materials will be evaluated for friction stir extrusion processes and the process parameters will be used. The machine described is being implemented in 3 phases. The first phase was the building of the basic machine and perform open-loop tests. The second phase was the implementation of process monitoring and begin to implement closed-loop control. The third phase of building the friction stir machine is to fully implement closed-loop control and begin charactering specific processes. This paper describes the current state of the project (Phase 2). A force transducer, thermocouple, and a displacement transducer are used to monitor the process parameters. A PLC is used to record the process parameters as well as control the 10HP 3-phase 240v ac electric motor that powers the rotating probe. Open-loop tests where the extrusion process was performed manually by the equipment operator were performed where the operators attempted to control forces during the tests and to perform component and system integration tests. A-1100-o aluminum solid billets 12.7mm in diameter were used to produce tubes (OD: 12.7-mm, ID: 6.35-mm). Observations, temperatures, and forces were recorded and are presented. Because this machine was a proof-of-concept machine that is being converted to a production machine, observations made will be used to improve the machine for Phase 3.
{"title":"The Development of a Friction Stir Extrusion Machine for Producing Multiscale Extruded Cylinders and Hollow Tubes","authors":"W. J. Emblom, Christopher Foreman, Charles Kreamer, Sydney E. Frazier, Seth Doiga, Michael Leaumont, Ayotunde Olayinka, P. Darby, Scott W. Wagner","doi":"10.1115/imece2022-89539","DOIUrl":"https://doi.org/10.1115/imece2022-89539","url":null,"abstract":"\u0000 Friction stir processing is being used to improve characteristics of advanced manufactured process by improving the strength and ductility of material, joining, surface characteristics, and alloying. In addition, friction stir processing may be used as a first step for recycling metallic waste.\u0000 The authors are interested in the friction stir processing because they see that friction stir extrusion may be used for producing unique components that could be useful for the development of fuel cells, micromanufacturing, heat exchangers, biomedical applications, and MEMS.\u0000 The goal of the current project is to develop a custom built friction stir machine in order to investigate multi-scale friction stir extrusion processes. The machine will be used to characterize various friction stir extrusion processes such as forward and backwards extrusion to produce solid cylinders and tubes with outside diameters up to 37-mm down to 3-mm and for tubes with internal diameters down to 2-mm. In addition, various materials will be evaluated for friction stir extrusion processes and the process parameters will be used.\u0000 The machine described is being implemented in 3 phases. The first phase was the building of the basic machine and perform open-loop tests. The second phase was the implementation of process monitoring and begin to implement closed-loop control. The third phase of building the friction stir machine is to fully implement closed-loop control and begin charactering specific processes.\u0000 This paper describes the current state of the project (Phase 2). A force transducer, thermocouple, and a displacement transducer are used to monitor the process parameters. A PLC is used to record the process parameters as well as control the 10HP 3-phase 240v ac electric motor that powers the rotating probe.\u0000 Open-loop tests where the extrusion process was performed manually by the equipment operator were performed where the operators attempted to control forces during the tests and to perform component and system integration tests.\u0000 A-1100-o aluminum solid billets 12.7mm in diameter were used to produce tubes (OD: 12.7-mm, ID: 6.35-mm). Observations, temperatures, and forces were recorded and are presented. Because this machine was a proof-of-concept machine that is being converted to a production machine, observations made will be used to improve the machine for Phase 3.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117155001","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper describes the effect of pass ratio on the forming quality of magnesium-aluminum composite pipes formed by multi-pass spinning. Established by NX software, the finite element simulation model of 7075 aluminum alloy-ZM21 magnesium alloy composite pipes was imported into Simufact. Forming software for simulation analysis. Based on previous research, the appropriate spinning parameters were selected. When the total reduction is constant, the ratios of three different reductions are studied and the final stress-strain results are obtained by finite element software simulation. By analyzing the straightness, cylindricity, and wall thickness of magnesium-aluminum composite pipes, the influence law of different pass reduction ratios on the surface quality of composite pipes is obtained. By analyzing the stress distribution of the magnesium-aluminum composite pipes interface, the influence law of different pass reduction ratios on the interface bonding strength of composite pipes is obtained. The final results show that compared with the initial pass, the contact stress on the surface of the magnesium-aluminum pipes in the subsequent pass is much greater than that in the initial pass. In the subsequent passes, the contact stress of the final pass has little difference. When the final pass reduction decreases, the cylindricity and straightness of the composite pipes decrease, so the surface quality of the composite pipes depends on the final pass reduction. Therefore, in the actual production process, the intermediate pass reduction can be increased and the final pass reduction can be appropriately reduced. These results provide technical guidance for the selection and optimization design of the reduction ratio of multipass spinning of magnesium-aluminum bimetallic composite pipes.
{"title":"Forming Quality Analysis of Mg-Al Composite Pipes of Multi-Pass Power Spinning","authors":"Jiabin Zheng, Xuedao Shu, Siyuan Chen, Qinying Lu","doi":"10.1115/imece2022-90413","DOIUrl":"https://doi.org/10.1115/imece2022-90413","url":null,"abstract":"\u0000 This paper describes the effect of pass ratio on the forming quality of magnesium-aluminum composite pipes formed by multi-pass spinning. Established by NX software, the finite element simulation model of 7075 aluminum alloy-ZM21 magnesium alloy composite pipes was imported into Simufact. Forming software for simulation analysis. Based on previous research, the appropriate spinning parameters were selected. When the total reduction is constant, the ratios of three different reductions are studied and the final stress-strain results are obtained by finite element software simulation. By analyzing the straightness, cylindricity, and wall thickness of magnesium-aluminum composite pipes, the influence law of different pass reduction ratios on the surface quality of composite pipes is obtained. By analyzing the stress distribution of the magnesium-aluminum composite pipes interface, the influence law of different pass reduction ratios on the interface bonding strength of composite pipes is obtained.\u0000 The final results show that compared with the initial pass, the contact stress on the surface of the magnesium-aluminum pipes in the subsequent pass is much greater than that in the initial pass. In the subsequent passes, the contact stress of the final pass has little difference. When the final pass reduction decreases, the cylindricity and straightness of the composite pipes decrease, so the surface quality of the composite pipes depends on the final pass reduction. Therefore, in the actual production process, the intermediate pass reduction can be increased and the final pass reduction can be appropriately reduced. These results provide technical guidance for the selection and optimization design of the reduction ratio of multipass spinning of magnesium-aluminum bimetallic composite pipes.","PeriodicalId":141381,"journal":{"name":"Volume 2A: Advanced Manufacturing","volume":"20 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122122469","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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