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Predictive modeling for online in-plane shape deviation inspection and compensation of additive manufacturing 用于在线平面形状偏差检测和增材制造补偿的预测模型
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-12-01 DOI: 10.1108/rpj-03-2023-0076
Hao Wang, Hamzeh Al Shraida, Yu Jin
PurposeLimited geometric accuracy is one of the major challenges that hinder the wider application of additive manufacturing (AM). This paper aims to predict in-plane shape deviation for online inspection and compensation to prevent error accumulation and improve shape fidelity in AM.Design/methodology/approachA sequence-to-sequence model with an attention mechanism (Seq2Seq+Attention) is proposed and implemented to predict subsequent layers or the occluded toolpath deviations after the multiresolution alignment. A shape compensation plan can be performed for the large deviation predicted.FindingsThe proposed Seq2Seq+Attention model is able to provide consistent prediction accuracy. The compensation plan proposed based on the predicted deviation can significantly improve the printing fidelity for those layers detected with large deviations.Practical implicationsBased on the experiments conducted on the knee joint samples, the proposed method outperforms the other three machine learning methods for both subsequent layer and occluded toolpath deviation prediction.Originality/valueThis work fills a research gap for predicting in-plane deviation not only for subsequent layers but also for occluded paths due to the missing scanning measurements. It is also combined with the multiresolution alignment and change point detection to determine the necessity of a compensation plan with updated G-code.
有限的几何精度是阻碍增材制造(AM)广泛应用的主要挑战之一。本文旨在预测平面内形状偏差,用于在线检测和补偿,以防止误差积累,提高增材制造的形状保真度。设计/方法/方法提出并实现了一种具有注意机制的序列到序列模型(Seq2Seq+ attention),用于预测多分辨率对准后的后续层或被遮挡的刀具轨迹偏差。对于预测的较大偏差,可以执行形状补偿方案。结果提出的Seq2Seq+Attention模型能够提供一致的预测精度。对于检测到的偏差较大的层,提出的基于预测偏差的补偿方案可以显著提高打印保真度。基于膝关节样本的实验,该方法在后续层和闭塞刀具轨迹偏差预测方面都优于其他三种机器学习方法。独创性/价值这项工作填补了预测平面内偏差的研究空白,不仅对后续层,而且对由于缺少扫描测量而遮挡的路径。它还与多分辨率对准和变化点检测相结合,以确定更新g代码的补偿计划的必要性。
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引用次数: 0
On 3D printed intelligent diaphragmatic hernia sensor 关于 3D 打印智能膈疝传感器
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-11-29 DOI: 10.1108/rpj-05-2023-0179
Rupinder Singh, Gurwinder Singh, Arun Anand
Purpose The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an Internet of Things (IOT)-based solution. Design/methodology/approach The approach used in this study is based on a bibliographic analysis for the re-occurrence of DH in the bovine after surgery. Using SolidWorks and ANSYS, the computer-aided design model of the implant was 3D printed based on literature and discussions on surgical techniques with a veterinarian. To ensure the error-proof design, load test and strain–stress rate analyses with boundary distortion have been carried out for the implant sub-assembly. Findings An innovative IOT-based additive manufacturing solution has been presented for the construction of a mesh-type sensor (for the health monitoring of bovine after surgery). Originality/value An innovative mesh-type sensor has been fabricated by integration of metal and polymer 3D printing (comprising 17–4 precipitate hardened stainless steel and polyvinylidene fluoride-hydroxyapatite-chitosan) without sacrificing strength and specific absorption ratio value.
目的 本文旨在设计和制造一种智能 3D 打印传感器,作为基于物联网(IOT)的解决方案,用于监测牛膈膜疝(DH;手术后)的再次发生。 设计/方法/途径 本研究采用的方法基于对牛手术后 DH 复发的文献分析。使用 SolidWorks 和 ANSYS,根据文献和与兽医讨论的手术技术,三维打印了植入物的计算机辅助设计模型。为确保设计无误,还对植入体子组件进行了载荷测试和边界变形应变应力率分析。 研究结果 提出了一种创新的基于物联网的增材制造解决方案,用于制造网状传感器(用于手术后牛的健康监测)。 原创性/价值 在不牺牲强度和比吸收比值的情况下,通过整合金属和聚合物三维打印技术(由 17-4 沉淀硬化不锈钢和聚偏氟乙烯-羟基磷灰石-壳聚糖组成),制造出了创新型网状传感器。
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引用次数: 0
Fabrication of continuous woven E-glass fiber composite using vat photopolymerization additive manufacturing process 使用大桶光聚合增材制造工艺制造连续编织 E 玻璃纤维复合材料
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-11-20 DOI: 10.1108/rpj-02-2023-0062
Annada Prasad Moharana, Ratnesh Raj, A. Dixit
Purpose The industrial application of continuous glass fabric-reinforced polymer composites (GFRPCs) is growing; however, the manufacturing boundedness of complex structures and the high cost of molds restrict their use. This research proposes a three-dimensional (3 D) printing process for GFRPCs that allows low-cost and rapid fabrication of complex composite parts. Design/methodology/approach The composite is manufactured using a digital light processing (DLP) based Vat-photopolymerization (VPP) process. For the composites, suitable resin material and glass fabrics are chosen based on their strength, stiffness, and printability. Jacob's working curve characterizes the curing parameters for adequate adhesion between the matrix and fabrics. The tensile and flexural properties were examined using UTM. The fabric distribution and compactness of the cured resin were analyzed in scanning electron microscopy. Findings The result showed that the object could print at a glass fabric content of 40 volume%. In DLP-based VPP printing technology, the adequate exposure time was found to be 30 seconds for making a GFRPC. The tensile strength and Young's modulus values were increased by 5.54 and 8.81 times, respectively than non-reinforced cured specimens. The flexural strength and modulus were also effectively increased to 2.8 and 3 times more than the neat specimens. In addition, the process is found to help fabricate the functional component. Originality/value The experimental procedure to fabricate GFRPC specimens through DLP-based AM is a spectacular experimental approach.
目的 连续玻璃纤维增强聚合物复合材料(GFRPCs)的工业应用正在不断增长;然而,复杂结构的制造限制和模具的高成本限制了其应用。本研究提出了玻璃纤维增强聚合物复合材料的三维(3 D)打印工艺,可低成本、快速地制造复杂的复合材料部件。 设计/方法/途径 采用基于数字光处理(DLP)的蒸镀-光聚合(VPP)工艺制造复合材料。根据强度、刚度和可印刷性,为复合材料选择合适的树脂材料和玻璃纤维织物。雅各布工作曲线表征了基体和织物之间充分粘合的固化参数。使用 UTM 对拉伸和弯曲性能进行了检测。用扫描电子显微镜分析了固化树脂的织物分布和致密性。 结果表明,玻璃纤维织物含量为 40% 时,物体可以进行打印。在基于 DLP 的 VPP 印刷技术中,发现制作 GFRPC 的适当曝光时间为 30 秒。拉伸强度和杨氏模量值分别比非增强固化试样提高了 5.54 倍和 8.81 倍。抗弯强度和模量也分别比未加固的试样有效提高了 2.8 倍和 3 倍。此外,该工艺还有助于制造功能部件。 独创性/价值 通过基于 DLP 的 AM 制作 GFRPC 试样的实验程序是一种引人注目的实验方法。
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引用次数: 0
Direct-print thermally responsive 4D textiles by depositing PLA on prestretched fabrics 通过在预拉伸织物上沉积聚乳酸,直接打印热响应 4D 纺织品
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-11-17 DOI: 10.1108/rpj-04-2023-0125
Jinyu Zhang, Danni Shen, yuxiang Yu, Defu Bao, Chao Li, Jiapei Qin
Purpose This study aims to develop a four-dimensional (4D) textile composite that self-forms upon thermal stimulation while eliminating thermomechanical programming steps by using fused deposition modeling (FDM) 3D printing technology, and tries to refine the product development path for this composite. Design/methodology/approach Polylactic acid (PLA) printing filaments were deposited on prestretched Lycra-knitted fabric using desktop-level FDM 3D printing technology to construct a three-layer structure of thermally responsive 4D textiles. Subsequently, the effects of different PLA thicknesses and Lycra knit fabric relative elongation on the permanent shape of thermally responsive 4D textiles were studied. Finally, a simulation program was written, and a case in this study demonstrates the usage of thermally responsive 4D textiles and the simulation program to design a wrist support product. Findings The constructed three-layer structure of PLA and Lycra knitted fabric can self-form under thermal stimulation. The material can also achieve reversible transformation between a permanent shape and multiple temporary shapes. Thinner PLA deposition and higher relative elongation of the Lycra-knitted fabric result in the greater curvature of the permanent shape of the thermally responsive 4D textile. The simulation program accurately predicted the permanent form of multiple basic shapes. Originality/value The proposed method enables 4D textiles to directly self-form upon thermal, which helps to improve the manufacturing efficiency of 4D textiles. The thermal responsiveness of the composite also contributes to building an intelligent human–material–environment interaction system.
目的 本研究旨在利用熔融沉积建模(FDM)三维打印技术开发一种四维(4D)纺织复合材料,该复合材料在热刺激下可自行成型,同时省去了热机械编程步骤,并尝试完善该复合材料的产品开发路径。 设计/方法/途径 利用桌面级 FDM 三维打印技术,将聚乳酸(PLA)打印长丝沉积在预拉伸莱卡针织面料上,构建三层结构的热响应 4D 纺织品。随后,研究了不同聚乳酸厚度和莱卡针织物相对伸长率对热响应 4D 纺织品永久形状的影响。最后,编写了一个仿真程序,并在本研究中通过一个案例演示了如何利用热响应 4D 纺织品和仿真程序设计手腕支撑产品。 研究结果 由聚乳酸和莱卡针织物构成的三层结构在热刺激下可自行成型。该材料还能在一个永久形状和多个临时形状之间实现可逆转换。更薄的聚乳酸沉积层和莱卡针织织物更高的相对伸长率使得热响应 4D 纺织品的永久形状具有更大的弧度。模拟程序准确预测了多种基本形状的永久形态。 原创性/价值 所提出的方法可使 4D 纺织品在受热后直接自成型,有助于提高 4D 纺织品的制造效率。复合材料的热响应性还有助于构建智能的人-材料-环境交互系统。
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引用次数: 0
Additively manufactured rectangular waveguides for the electromagnetic characterization of materials using the transmission/reflection line method 使用透射/反射线方法对材料进行电磁特性表征的加材制造矩形波导
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-11-10 DOI: 10.1108/rpj-06-2023-0197
Connor Shane Smith, Alanna Julius, Christian Arbeeny, John Davenport Stevens
Purpose Radio frequency (RF) technology relies on the electromagnetic properties of the materials used, which includes their complex permittivities and loss tangents. To measure these properties, techniques for material characterization such as the transmission/reflection method are used in conjunction with conversion techniques to calculate these values from scattering parameters. Unfortunately, these techniques rely on relatively expensive rectangular waveguide adaptors and components, especially if testing over large frequency ranges. This paper aims to overcome this challenge by developing a more affordable test equipment solution based on additively manufactured waveguide sections. Design/methodology/approach To evaluate the effectiveness of using additively manufactured waveguides to perform electromagnetic characterization with the transmission/reflection method, samples of PLA Tough with varying infill percentages and samples made from several Formlabs photopolymer resins are fabricated and analyzed. Findings Results show that the method yielded permittivity and loss tangent values for the measured materials that generally agree with those found in the literature, supporting its credibility. Originality/value The accessibility of this measurement technique will ideally allow for more electromagnetic material characterization to occur and expand the possible use of additive manufacturing in future RF designs. This work also provides characterization of several Formlabs photopolymer resins, which have not been widely analyzed in the current literature.
射频(RF)技术依赖于所用材料的电磁特性,包括其复杂的介电常数和损耗切线。为了测量这些特性,材料表征技术(如透射/反射法)与转换技术结合使用,从散射参数计算这些值。不幸的是,这些技术依赖于相对昂贵的矩形波导适配器和组件,特别是在大频率范围内进行测试时。本文旨在通过开发一种基于增材制造波导截面的更经济实惠的测试设备解决方案来克服这一挑战。为了评估使用增材制造波导进行透射/反射法电磁表征的有效性,制作并分析了不同填充百分比的PLA Tough样品和几种Formlabs光聚合物树脂制成的样品。结果表明,该方法得到的测量材料的介电常数和损耗正切值与文献中发现的值基本一致,支持其可信度。这种测量技术的可访问性将理想地允许更多的电磁材料特性发生,并扩大增材制造在未来RF设计中的可能使用。这项工作还提供了几种Formlabs光聚合物树脂的表征,这些树脂在当前文献中尚未得到广泛分析。
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引用次数: 0
Numerical and experimental investigation on the heat transfer and mass transport in LPBF in-situ alloying of Al/Cu alloy Al/Cu合金LPBF原位合金化传热传质的数值与实验研究
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-11-08 DOI: 10.1108/rpj-01-2023-0015
Yang Zhou, Zhong Li, Yuhe Huang, Xiaohan Chen, Xinggang Li, Xiaogang Hu, Qiang Zhu
Purpose Laser powder bed fusion (LPBF) in-situ alloying is a recently developed technology that provides a facile approach to optimizing the microstructural and compositional characteristics of the components for high performance goals. However, the complex mass and heat transfer behavior of the molten pool results in an inhomogeneous composition distribution within the samples fabricated by LPBF in-situ alloying. The study aims to investigate the heat and mass transfer behavior of an in-situ alloyed molten pool by developing a three-dimensional transient thermal-flow model that couples the metallurgical behavior of the alloy, thereby revealing the formation mechanism of composition inhomogeneity. Design/methodology/approach A multispecies multiphase computational fluid dynamic model was developed with thermodynamic factors derived from the phase diagram of the selected alloy system. The characteristics of the Al/Cu powder bed in-situ alloying process were investigated as a benchmark. The metallurgical behaviors including powder melting, thermal-flow, element transfer and solidification were investigated. Findings The Peclet number indicates that the mass transfer in the molten pool is dominated by convection. The large variation in material properties and temperature results in the presence of partially melted Cu-powder and pre-solidified particles in the molten pool, which further hinder the convection mixing. The study of simulation and experiment indicates that optimizing the laser energy input is beneficial for element homogenization. The effective time and driving force of the convection stirring can be improved by increasing the volume energy density. Originality/value This study provides an in-depth understanding of the formation mechanism of composition inhomogeneity in alloy fabricated by LPBF in-situ alloying.
激光粉末床原位合金化(LPBF)是近年来发展起来的一项新技术,它提供了一种简便的方法来优化部件的显微组织和成分特征,以达到高性能的目标。然而,由于熔池复杂的传质传热行为,导致LPBF原位合金化制备的样品中成分分布不均匀。本研究旨在通过建立耦合合金冶金行为的三维瞬态热流模型,研究原位合金熔池的传热传质行为,从而揭示成分不均匀性的形成机制。设计/方法/方法基于所选合金体系相图的热力学因素,建立了多组分多相流体力学计算模型。以Al/Cu粉末床原位合金化工艺为基准,研究了原位合金化工艺的特点。研究了粉末熔化、热流、元素传递和凝固等冶金行为。发现Peclet数表明熔池内的传质以对流为主。由于材料性能和温度的较大变化,导致熔池中存在部分熔化的铜粉和预固化颗粒,进一步阻碍了对流混合。仿真和实验研究表明,优化激光能量输入有利于元件均匀化。增大体积能量密度可以提高对流搅拌的有效时间和驱动力。本研究为LPBF原位合金化制备的合金中成分不均匀性的形成机制提供了深入的认识。
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引用次数: 0
Multimaterial 3D printing of auxetic jounce bumpers for automotive suspensions 汽车悬架减震保险杠的多材料3D打印
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-10-31 DOI: 10.1108/rpj-02-2023-0066
Alberto Giubilini, Paolo Minetola
Purpose The purpose of this study is to evaluate the 3D printability of a multimaterial, fully self-supporting auxetic structure. This will contribute to expanding the application of additive manufacturing (AM) to new products, such as automotive suspensions. Design/methodology/approach An experimental approach for sample fabrication on a multiextruder 3D printer and characterization by compression testing was conducted along with numerical simulations, which were used to support the design of different auxetic configurations for the jounce bumper. Findings The effect of stacking different auxetic cell modules was discussed, and the findings demonstrated that a one-piece printed structure has a better performance than one composed of multiple single modules stacked on top of each other. Research limitations/implications The quality of the 3D printing process affected the performance of the final components and reproducibility of the results. Therefore, researchers are encouraged to further study component fabrication optimization to achieve a more reliable process. Practical implications This research work can help improve the manufacturing and functionality of a critical element of automotive suspension systems, such as the jounce bumper, which can efficiently reduce noise, vibration and harshness by absorbing impact energy. Originality/value In previous research, auxetic structures for the application of jounce bumpers have already been suggested. However, to the best of the authors’ knowledge, in this work, an AM approach was used for the first time to fabricate multimaterial auxetic structures, not only by co-printing a flexible thermoplastic polymer with a stiffer one but also by continuously extruding multilevel structures of auxetic cell modules.
本研究的目的是评估一种多材料、完全自支撑的辅助结构的3D可打印性。这将有助于扩大增材制造(AM)在汽车悬架等新产品中的应用。设计/方法/方法在多挤出机3D打印机上进行了样品制作的实验方法,并通过压缩测试进行了表征,同时进行了数值模拟,用于支持缓冲缓冲器不同辅助配置的设计。结果表明,单件打印结构的性能优于多个单模块堆叠结构。研究限制/启示3D打印过程的质量影响最终组件的性能和结果的可重复性。因此,鼓励研究人员进一步研究元件制造优化,以实现更可靠的工艺。这项研究工作可以帮助改善汽车悬架系统的关键部件的制造和功能,例如缓冲器,它可以通过吸收冲击能量来有效地降低噪音、振动和粗糙度。在以前的研究中,已经提出了用于减震缓冲器的减震结构。然而,据作者所知,在这项工作中,AM方法首次用于制造多材料的消声结构,不仅通过与刚性聚合物共打印柔性热塑性聚合物,而且还通过连续挤出消声细胞模块的多层结构。
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引用次数: 0
Investigation and optimization of hot pressed porcelain dental prostheses production by MSLA application MSLA应用于热压烤瓷义齿生产的研究与优化
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-10-30 DOI: 10.1108/rpj-05-2023-0180
Ana Carla Cordeiro, Gustavo George Verdieri Nuernberg, Lilian Cristina Côcco, Marlon Wesley Machado Cunico
Purpose Different technologies may currently be used to produce dental prostheses, such as additive manufacturing and traditional milling. This study aims to evaluate and improve the fabrication process for hot-pressed porcelain dental prostheses and compare the use of masked stereolithography apparatus (MSLA) casting to computer-aided design/computer-aided manufacturing (CAD/CAM) casting. The cost-benefit analysis of producing dental prostheses through various technologies, including additive manufacturing and traditional milling, has not been fully explored. The cost of materials and processes used to produce prostheses varies based on complexity of design and materials used, and long-term effects, such as durability and wear and tear, must be taken into account. Design/methodology/approach Using key elements of part costs and estimation cost models, a multivariable approach was used to evaluate the practicality of the recommended strategy and process improvement. Findings The research found that MSLA casting provides a higher return on investment than CAD/CAM casting, and the optimized production process could be more suitable for the size and annual demand for prostheses. Originality/value Overall, this study highlights the need for a more comprehensive understanding of the cost-benefit analysis of different dental prosthesis production methods and emphasises the importance of evaluating long-term effects on the cost-benefit analysis.
目前可以使用不同的技术来生产义齿,例如增材制造和传统铣削。本研究旨在评估和改进热压烤瓷义齿的制造工艺,并将掩模立体光刻设备(MSLA)铸造与计算机辅助设计/计算机辅助制造(CAD/CAM)铸造进行比较。通过各种技术(包括增材制造和传统铣削)生产牙修复体的成本效益分析尚未得到充分探索。用于生产假肢的材料和工艺的成本因设计和所用材料的复杂性而异,并且必须考虑到长期影响,例如耐用性和磨损。设计/方法/方法使用零件成本和估算成本模型的关键要素,采用多变量方法来评估推荐策略和流程改进的实用性。研究发现,MSLA铸造比CAD/CAM铸造具有更高的投资回报率,优化后的生产工艺更适合义肢的尺寸和年需求量。总体而言,本研究强调需要更全面地了解不同义齿生产方法的成本效益分析,并强调评估成本效益分析的长期影响的重要性。
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引用次数: 0
Method for manufacturing ergonomic bespoke external breast prostheses using low-cost computer-aided technology 利用低成本计算机辅助技术制造符合人体工程学的定制乳房外部假体的方法
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-10-25 DOI: 10.1108/rpj-06-2023-0200
Lucia Regina, José Aguiomar Foggiatto
Purpose Breast cancer is the most diagnosed type of cancer in the world, and mastectomies to remove tumors are still common. An external breast prosthesis (EBP) can be used to minimize the asymmetry, due to the ablation. Some governments do not cover costs of that assistive technology, and women end up using socks and fabric pockets filled with seeds, to simulate the volume lost in the surgery. This study aims to offer to those women a decent solution, ergonomic, but still affordable. Design/methodology/approach The authors interviewed 20 mastectomized Brazilian women, listened to their relate and 3D scanned them, to give rise to personalized external lightweight breast prostheses. The authors used free software for computer-aided design and computer-aided manufacturing, and low-cost 3D printers. From the strategy of bespoke products, this study generalized the method, to conceive mass customized prostheses, in a compromise solution that reduces personalization, conserving the best features of design. Findings This study achieved a method to manufacture ergonomic, bespoke external breast prostheses, using low-cost technology. Previous literature made them using expensive scanners, software and printers. Research limitations/implications The authors validated this method during pandemic, which restricted the number of patients the authors could have access to. This impacted authors’ possibility to work on matching the color of the final product and real skin. The authors understood, though, that precision of color, in the final product, is challenging, because of the peculiar aspects of human skin. Originality/value Using the method the authors proposed, personalized external breast prostheses can be manufactured using low-cost resources, democratizing better quality of life for more breast cancer survivors.
乳腺癌是世界上诊断最多的癌症类型,乳房切除术切除肿瘤仍然很常见。外部乳房假体(EBP)可以减少消融造成的不对称。一些政府不承担这种辅助技术的费用,女性最终使用装满种子的袜子和织物口袋来模拟手术中损失的体积。这项研究旨在为这些女性提供一个体面的解决方案,符合人体工程学,但仍然负担得起。设计/方法/方法作者采访了20名切除乳房的巴西女性,听取她们的诉说,并对她们进行3D扫描,以产生个性化的外部轻量级乳房假体。作者使用了计算机辅助设计和计算机辅助制造的免费软件,以及低成本的3D打印机。本研究从定制产品的策略出发,将该方法推广到大规模定制假肢,在减少个性化的同时,保留设计的最佳特征。本研究实现了一种低成本、符合人体工程学的定制乳房外假体制造方法。以前的文献使用昂贵的扫描仪、软件和打印机。研究局限性/启示作者在大流行期间验证了这种方法,这限制了作者可以接触到的患者数量。这影响了作者将最终产品的颜色与真实皮肤相匹配的可能性。然而,作者明白,由于人类皮肤的特殊特性,最终产品的颜色精度是具有挑战性的。使用作者提出的方法,可以使用低成本的资源制造个性化的外部乳房假体,为更多的乳腺癌幸存者提供更好的生活质量。
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引用次数: 0
Development of process-structure linkage for Inconel 718 processed by laser powder bed fusion: a numerical modeling approach 激光粉末床熔合Inconel 718工艺结构联动的数值模拟方法研究
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-10-19 DOI: 10.1108/rpj-02-2023-0064
Anuj Kumar, Mukul Shukla
Purpose Understanding and tailoring the solidification characteristics and microstructure evolution in as-built parts fabricated by laser powder bed fusion (LPBF) is crucial as they influence the final properties. Experimental approaches to address this issue are time and capital-intensive. This study aims to develop an efficient numerical modeling approach to develop the process–structure (P-S) linkage for LPBF-processed Inconel 718. Design/methodology/approach In this study, a numerical approach based on the finite element method and cellular automata was used to model the multilayer, multitrack LPBF build for predicting the solidification characteristics (thermal gradient G and solidification rate R) and the average grain size. Validations from published experimental studies were also carried out to ensure the reliability of the proposed numerical approach. Furthermore, microstructure simulations were used to develop P-S linkage by evaluating the effects of key LPBF process parameters on G × R, G/R and average grain size. A solidification or G-R map was also developed to comprehend the P-S linkage. Findings It was concluded from the developed G-R map that low laser power and high scan speed will result in a finer microstructure due to an increase in G × R, but due to a decrease in G/R, columnar characteristics are also reduced. Moreover, increasing the layer thickness and decreasing the hatch spacing lowers the G × R, raises the G/R and generates a coarse columnar microstructure. Originality/value The proposed numerical modeling approach was used to parametrically investigate the effect of LPBF parameters on the resulting microstructure. A G-R map was also developed that enables the tailoring of the as-built LPBF microstructure through solidification characteristics by tuning the process parameters.
目的了解和调整激光粉末床熔合成形零件的凝固特性和微观组织演变是至关重要的,因为它们会影响最终性能。解决这一问题的实验性方法需要耗费大量时间和资金。本研究旨在开发一种有效的数值模拟方法来开发lpbf加工的Inconel 718的工艺结构(P-S)联系。设计/方法/方法在本研究中,采用基于有限元法和元胞自动机的数值方法对多层、多径LPBF构建进行建模,以预测凝固特性(热梯度G和凝固速率R)和平均晶粒尺寸。已发表的实验研究也进行了验证,以确保所提出的数值方法的可靠性。此外,通过微观组织模拟,评估LPBF关键工艺参数对G × R、G/R和平均晶粒尺寸的影响,建立了P-S连锁。还开发了凝固或G-R图来理解P-S联系。结果表明,低激光功率和高扫描速度会使材料的G × R增大,从而获得更细的微观结构,但G/R的减小也会降低材料的柱状特征。增大焊层厚度和减小焊口间距降低了gxr,提高了G/R,形成了粗糙的柱状组织。采用所提出的数值模拟方法,参数化研究了LPBF参数对所得微观结构的影响。还开发了G-R图,通过调整工艺参数,通过凝固特性来定制已建成的LPBF微观结构。
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引用次数: 0
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Rapid Prototyping Journal
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