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Additively manufactured medical bone screws: an initial study to investigate the impact of lattice-based Voronoi structure on implant primary stability 增材制造医用骨螺钉:一项初步研究格状Voronoi结构对种植体初级稳定性的影响
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-26 DOI: 10.1108/rpj-10-2022-0363
Chiara Bregoli, Jacopo Fiocchi, Carlo Alberto Biffi, Ausonio Tuissi
Purpose The present study investigates the mechanical properties of three types of Ti6Al4V ELI bone screws realized using the laser powder bed fusion (LPBF) process: a fully threaded screw and two groups containing differently arranged sectors made of lattice-based Voronoi (LBV) structure in a longitudinal and transversal position, respectively. This study aims to explore the potentialities related to the introduction of LBV structure and assess its impact on the implant’s primary stability and mechanical performance. Design/methodology/approach The optimized bone screw designs were realized using the LPBF process. The quality and integrity of the specimens were assessed by scanning electron microscopy and micro-computed tomography. Primary stability was experimentally verified by the insertion and removal of the screws in standard polyurethane foam blocks. Finally, torsional tests were carried out to compare and assess the mechanical strength of the different designs. Findings The introduction of the LBV structure decreases the elastic modulus of the implant. Longitudinal LBV type screws demonstrated the lowest insertion torque (associated with lower bone damage) while still displaying promising torsional strength and removal force compared with full-thread screws. The use of LBV structure can promote improved functional performances with respect to the reference thread, enabling the use of lattice structures in the biomedical sector. Originality/value The paper fulfils an identified interest in designing customized implants with improved primary stability and promising features for secondary stability.
目的研究激光粉末床融合(LPBF)工艺制备的三种Ti6Al4V ELI骨螺钉的力学性能:一种全螺纹螺钉和两组由晶格型Voronoi (LBV)结构组成的不同排列扇区分别在纵向和横向位置。本研究旨在探讨引入LBV结构的可能性,并评估其对种植体初级稳定性和力学性能的影响。设计/方法/方法采用LPBF工艺实现了优化的骨螺钉设计。通过扫描电子显微镜和显微计算机断层扫描评估标本的质量和完整性。通过在标准聚氨酯泡沫块中插入和取出螺钉,实验验证了初级稳定性。最后,进行了扭转试验,比较和评价了不同设计的机械强度。LBV结构的引入降低了种植体的弹性模量。与全螺纹螺钉相比,纵向LBV型螺钉具有最低的插入扭矩(与较低的骨损伤相关),同时仍具有良好的扭转强度和拆除力。LBV结构的使用可以提高参考线程的功能性能,使晶格结构能够在生物医学领域使用。原创性/价值该论文满足了设计定制植入物的确定兴趣,该植入物具有改进的初级稳定性和有希望的次级稳定性特征。
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引用次数: 1
Explainable deep neural network for in-plain defect detection during additive manufacturing 可解释深度神经网络在增材制造过程中的缺陷检测
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-26 DOI: 10.1108/rpj-05-2023-0157
Deepak Kumar, Yongxin Liu, Houbing Song, Sirish Namilae
Purpose The purpose of this study is to develop a deep learning framework for additive manufacturing (AM), that can detect different defect types without being trained on specific defect data sets and can be applied for real-time process control. Design/methodology/approach This study develops an explainable artificial intelligence (AI) framework, a zero-bias deep neural network (DNN) model for real-time defect detection during the AM process. In this method, the last dense layer of the DNN is replaced by two consecutive parts, a regular dense layer denoted (L1) for dimensional reduction, and a similarity matching layer (L2) for equal weight and non-biased cosine similarity matching. Grayscale images of 3D printed samples acquired during printing were used as the input to the zero-bias DNN. Findings This study demonstrates that the approach is capable of successfully detecting multiple types of defects such as cracks, stringing and warping with high accuracy without any prior training on defective data sets, with an accuracy of 99.5%. Practical implications Once the model is set up, the computational time for anomaly detection is lower than the speed of image acquisition indicating the potential for real-time process control. It can also be used to minimize manual processing in AI-enabled AM. Originality/value To the best of the authors’ knowledge, this is the first study to use zero-bias DNN, an explainable AI approach for defect detection in AM.
本研究的目的是为增材制造(AM)开发一个深度学习框架,该框架可以检测不同的缺陷类型,而无需接受特定缺陷数据集的训练,并可应用于实时过程控制。本研究开发了一个可解释的人工智能(AI)框架,一个用于增材制造过程中实时缺陷检测的零偏差深度神经网络(DNN)模型。在该方法中,将DNN的最后一个密集层替换为两个连续的部分,一个表示为降维的规则密集层(L1)和一个表示为等权和无偏余弦相似匹配的相似匹配层(L2)。将打印过程中获取的3D打印样品的灰度图像作为零偏差深度神经网络的输入。本研究表明,该方法能够在不需要对缺陷数据集进行任何预先训练的情况下,以高精度成功检测出多种类型的缺陷,如裂纹、串和翘曲,准确率达到99.5%。一旦模型建立,异常检测的计算时间低于图像采集的速度,这表明了实时过程控制的潜力。它还可以用于减少人工智能AM中的人工处理。据作者所知,这是第一个使用零偏差深度神经网络的研究,这是一种可解释的人工智能方法,用于增材制造中的缺陷检测。
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引用次数: 0
Rapid prototyping of 3d printed micropillars using fused filament fabrication technique for biomedical applications 生物医学应用中使用熔丝制造技术的3d打印微柱的快速原型制作
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-20 DOI: 10.1108/rpj-03-2023-0096
Shamima Khatoon, Gufran Ahmad
Purpose The hygroscopic properties of 3D-printed filaments and moisture absorption itself during the process result in dimensional inaccuracy, particularly for nozzle movement along the x-axis and for micro-scale features. In view of that, this study aims to analyze in depth the dimensional errors and deviations of the fused filament fabrication (FFF)/fused deposition modeling (FDM) 3D-printed micropillars (MPs) from the reference values. A detailed analysis into the variability in printed dimensions below 1 mm in width without any deformations in the printed shape of the designed features, for challenging filaments like polymethyl methacrylate (PMMA) has been done. The study also explores whether the printed shape retains the designed structure. Design/methodology/approach A reference model for MPs of width 800 µm and height 2,000 µm is selected to generate a g-code model after pre-processing of slicing and meshing parameters for 3D printing of micro-scale structure with defined boundaries. Three SETs, SET-A, SET-B and SET-C, for nozzle diameter of 0.2 mm, 0.25 mm and 0.3 mm, respectively, have been prepared. The SETs containing the MPs were fabricated with the spacing (S) of 2,000 µm, 3,200 µm and 4,000 µm along the print head x-axis. The MPs were measured by taking three consecutive measurements (top, bottom and middle) for the width and one for the height. Findings The prominent highlight of this study is the successful FFF/FDM 3D printing of thin features (<1mm) without any deformation. The mathematical analysis of the variance of the optical microscopy measurements concluded that printed dimensions for micropillar widths did not vary significantly, retaining more than 65% of the recording within the first standard deviation (SD) (±1 s). The minimum value of SD is obtained from the samples of SET-B, that is, 31.96 µm and 35.865 µm, for height and width, respectively. The %RE for SET-B samples is 5.09% for S = 2,000µm, 3.86% for S = 3,200µm and 1.09% for S = 4,000µm. The error percentage is so small that it could be easily compensated by redesigning. Research limitations/implications The study does not cover other 3D printing techniques of additive manufacturing like stereolithography, digital light processing and material jetting. Practical implications The presented study can be potentially implemented for the rapid prototyping of microfluidics mixer, bioseparator and lab-on-chip devices, both for membrane-free bioseparation based on microfiltration, plasma extraction from whole blood, size-selection trapping of unwanted blood cells, and also for membrane-based plasma extraction that requires supporting microstructures. Our developed process may prove to be far more economical than the other existing techniques for such applications. Originality/value For the first time, this work presents a comprehensive analysis of the fabrication of micropillars using FDM/FFF 3D printing and PMMA in filament form. The primary focus of the study is to min
3d打印长丝的吸湿特性和过程中的吸湿性导致尺寸不准确,特别是喷嘴沿x轴运动和微尺度特征。鉴于此,本研究旨在从参考值出发,深入分析熔丝制造(FFF)/熔丝沉积建模(FDM) 3d打印微柱(MPs)的尺寸误差和偏差。对于具有挑战性的长丝,如聚甲基丙烯酸甲酯(PMMA),已经对宽度小于1毫米的印刷尺寸的可变性进行了详细分析,而印刷形状的设计特征没有任何变形。该研究还探讨了打印形状是否保留了设计结构。设计/方法/方法选择宽度为800µm、高度为2000µm的MPs作为参考模型,对具有定义边界的微尺度结构进行切片和网格参数预处理后生成g代码模型。制备了喷嘴直径分别为0.2 mm、0.25 mm和0.3 mm的SET-A、SET-B和SET-C三组。在打印头x轴上分别制作了2000µm、3200µm和4000µm的包含MPs的set。MPs通过连续三次测量(顶部,底部和中间)来测量宽度,一次测量高度。本研究的突出亮点是成功的FFF/FDM 3D打印薄特征(<1mm),无任何变形。对光学显微镜测量结果方差的数学分析表明,微柱宽度的印刷尺寸变化不显著,在第一标准偏差(SD)(±1 s)内保留了65%以上的记录。SET-B样品的最小SD值分别为31.96µm和35.865µm,分别为高和宽。S = 2000µm时,SET-B样品的RE %为5.09%,S = 3200µm时为3.86%,S = 4000µm时为1.09%。误差百分比很小,可以很容易地通过重新设计来补偿。该研究不包括其他增材制造的3D打印技术,如立体光刻、数字光处理和材料喷射。本研究可用于微流体混合器、生物分离器和芯片实验室设备的快速原型设计,既可用于基于微过滤的无膜生物分离、全血血浆提取、不需要的血细胞的尺寸选择捕获,也可用于需要支持微结构的基于膜的血浆提取。我们开发的工艺可能被证明比其他现有的用于此类应用的技术更经济。这是第一次,这项工作对使用FDM/FFF 3D打印和长丝形式的PMMA制造微柱进行了全面的分析。该研究的主要重点是通过从参数的选择中获得好处,最大限度地减少包含薄特征的3D打印设备的尺寸不准确性,特别是在生物医学工程领域。因此,在误差和偏差的基础上,对三组制备的微柱进行了全面的比较。
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引用次数: 1
Development and characterization of composite materials with multi-walled carbon nanotubes and graphene nanoplatelets for powder bed fusion 多壁碳纳米管和石墨烯纳米片粉末床熔合复合材料的研制与表征
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-18 DOI: 10.1108/rpj-04-2023-0142
Ana C. Lopes, Álvaro M. Sampaio, António J. Pontes
Purpose With the technological progress, high-performance materials are emerging in the market of additive manufacturing to comply with the advanced requirements demanded for technical applications. In selective laser sintering (SLS), innovative powder materials integrating conductive reinforcements are attracting much interest within academic and industrial communities as promising alternatives to common engineering thermoplastics. However, the practical implementation of functional materials is limited by the extensive list of conditions required for a successful laser-sintering process, related to the morphology, powder size and shape, heat resistance, melt viscosity and others. The purpose of this study is to explore composite materials of polyamide 12 (PA12) incorporating multi-walled carbon nanotubes (MWCNT) and graphene nanoplatelets (GNP), aiming to understand their suitability for advanced SLS applications. Design/methodology/approach PA12-MWCNT and PA12-GNP materials were blended through a pre-optimized process of mechanical mixing with various percentages of reinforcement between 0.50 wt.% and 3.00 wt.% and processed by SLS with appropriate volume energy density. Several test specimens were produced and characterized with regard to processability, thermal, mechanical, electrical and morphological properties. Finally, a comparative analysis of the performance of both carbon-based materials was performed. Findings The results of this research demonstrated easier processability and higher tensile strength and impact resistance for composites incorporating MWCNT but higher tensile elastic modulus, compressive strength and microstructural homogeneity for GNP-based materials. Despite the decrease in mechanical properties, valuable results of electrical conductivity were obtained with both carbon solutions until 10 –6 S/cm. Originality/value The carbon-based composites developed in this research allow for the expansion of the applicability of laser-sintered parts to advanced fields, including electronics-related industries that require functional materials capable of protecting sensitive devices against electrostatic discharge.
随着技术的进步,高性能材料在增材制造市场不断涌现,以满足技术应用的先进要求。在选择性激光烧结(SLS)中,集成导电增强的创新粉末材料作为普通工程热塑性塑料的有前途的替代品,引起了学术界和工业界的极大兴趣。然而,功能材料的实际实施受到成功激光烧结工艺所需的大量条件的限制,这些条件与形貌、粉末尺寸和形状、耐热性、熔体粘度等有关。本研究的目的是探索含有多壁碳纳米管(MWCNT)和石墨烯纳米片(GNP)的聚酰胺12 (PA12)复合材料,旨在了解其在先进SLS应用中的适用性。通过预先优化的机械混合工艺,将PA12-MWCNT和PA12-GNP材料混合在0.50 wt.%和3.00 wt.%之间的不同比例的增强剂中,并通过SLS以适当的体积能量密度进行处理。制作了几个测试样品,并对其加工性,热学,机械,电学和形态学特性进行了表征。最后,对两种碳基材料的性能进行了比较分析。研究结果表明,含有MWCNT的复合材料更容易加工,抗拉强度和抗冲击性更高,但gnp基材料的拉伸弹性模量、抗压强度和微观结构均匀性更高。尽管力学性能下降,但在10 -6 S/cm之前,两种碳溶液都获得了有价值的电导率结果。本研究中开发的碳基复合材料允许将激光烧结部件的适用性扩展到先进领域,包括需要能够保护敏感设备免受静电放电的功能材料的电子相关行业。
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引用次数: 0
Influence of copper interlayer on the interface characteristics of stainless steel–aluminium transitional structure in wire arc directed energy deposition 铜夹层对线弧定向能沉积中不锈钢-铝过渡结构界面特性的影响
4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-12 DOI: 10.1108/rpj-03-2023-0089
Amrit Raj Paul, Manidipto Mukherjee, Mohit Kumar Sahu
Purpose The purpose of this study is to investigate the deposition of SS–Al transitional wall using the wire arc directed energy deposition (WA-DED) process with a Cu interlayer. This study also aims to analyse the metallographic properties of the SS–Cu and Al–Cu interfaces and their mechanical properties. Design/methodology/approach The study used transitional deposition of SS–Al material over each other by incorporating Cu as interlayer between the two. The scanning electron microscope analysis, energy dispersive X-ray analysis, X-ray diffractometer analysis, tensile testing and micro-hardness measurement were performed to investigate the interface characteristics and mechanical properties of the SS–Al transitional wall. Findings The study discovered that the WA-DED process with a Cu interlayer worked well for the deposition of SS–Al transitional walls. The formation of solid solutions of Fe–Cu and Fe–Si was observed at the SS–Cu interface rather than intermetallic compounds (IMCs), according to the metallographic analysis. On the other hand, three different IMCs were formed at the Al–Cu interface, namely, Al–Cu, Al 2 Cu and Al 4 Cu 9 . The study also observed the formation of a lamellar structure of Al and Al 2 Cu at the hypereutectic phase. The mechanical testing revealed that the Al–Cu interface failed without significant deformation, i.e. < 4.73%, indicating the brittleness of the interface. Originality/value The study identified the formation of HCP–Fe at the SS–Cu interface, which has not been previously reported in additive manufacturing literature. Furthermore, the study observed the formation of a lamellar structure of Al and Al2Cu phase at the hypereutectic phase, which has not been previously reported in SS–Al transitional wall deposition.
本研究的目的是研究采用带Cu中间层的电弧定向能沉积(WA-DED)工艺沉积SS-Al过渡壁。本研究还旨在分析SS-Cu和Al-Cu界面的金相性能及其力学性能。设计/方法/方法本研究采用SS-Al材料的过渡沉积,将Cu作为两者之间的中间层。采用扫描电镜分析、能量色散x射线分析、x射线衍射分析、拉伸测试和显微硬度测试等方法研究了SS-Al过渡壁的界面特征和力学性能。研究发现,采用带Cu中间层的WA-DED工艺可以很好地沉积SS-Al过渡壁。根据金相分析,Fe-Cu和Fe-Si的固溶体是在SS-Cu界面形成的,而不是金属间化合物(IMCs)。另一方面,在Al - Cu界面处形成了3种不同的IMCs,分别是Al - Cu、Al - 2cu和Al - 4cu - 9。研究还观察到在过共晶相形成Al和al2cu的片层结构。力学性能测试表明,Al-Cu界面破坏,但没有明显变形,即<4.73%,表示界面脆性。该研究确定了SS-Cu界面上HCP-Fe的形成,这在增材制造文献中尚未报道。此外,本研究还观察到在过共晶相中形成Al和Al2Cu相的片层结构,这在SS-Al过渡壁沉积中尚未见报道。
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引用次数: 0
Exploring innovation system dynamics: event history analysis of the evolution of the South African additive manufacturing industry 探索创新系统动力学:南非增材制造业演变的事件历史分析
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-08 DOI: 10.1108/rpj-04-2023-0143
Michelle McClelland, Sara Grobbelaar, N. Sacks
PurposeThis paper aims to explore the growth of the South African additive manufacturing (AM) industry over the past 31 years through the lens of the innovation system (IS) perspective, examining the actor dynamics and mechanisms that facilitated or hindered the industry’s development.Design/methodology/approachThe study used a case study research approach, analysing semi-structured interviews with eight South African AM experts and documentary evidence. The IS framework and the realist evaluation perspective were used, using a context-intervention-mechanism-outcome (CIMO)-based event history analysis (EHA) framework to explore the actor dynamics and mechanisms of the case study.FindingsThe study used a case study research approach, analysing semi-structured interviews with eight South African AM experts and documentary evidence. The IS framework and the realist evaluation perspective were used, using a CIMO-based EHA framework to explore the actor dynamics and mechanisms of the case study.Originality/valueThis paper contributes to the South African AM industry literature by providing an overview of the industry events over the past three decades and analysing the industry through the IS framework. The study is among the first to analyse the development of the South African AM industry, presenting innovation scholars and managers with valuable decision-making support by providing insights into the innovation activities performed during each stage of the industry’s development, who performed them, the sequence in which they were performed and the outcomes they delivered.
目的本文旨在探讨南非增材制造业在过去31年中的增长情况 多年来,通过创新系统(IS)的视角,考察促进或阻碍行业发展的参与者动态和机制。设计/方法/方法该研究采用了案例研究的方法,分析了对八名南非AM专家的半结构化访谈和文件证据。采用IS框架和现实主义评价视角,采用基于情境干预机制-结果(CIMO)的事件历史分析(EHA)框架,探讨案例研究的参与者动态和机制。发现该研究采用了案例研究的方法,分析了对八名南非AM专家的半结构化访谈和文件证据。采用IS框架和现实主义评价视角,使用基于CIMO的EHA框架来探索案例研究的参与者动态和机制。原创性/价值本文概述了过去三十年的行业事件,并通过IS框架分析了该行业,从而为南非AM行业文献做出了贡献。这项研究是首批分析南非AM行业发展的研究之一,通过深入了解行业发展每个阶段的创新活动、谁进行了创新活动、实施顺序和结果,为创新学者和管理者提供了宝贵的决策支持。
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引用次数: 0
Dynamic response of 3D printed functionally graded sandwich foams 3D打印功能梯度夹层泡沫的动态响应
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-07 DOI: 10.1108/rpj-01-2023-0016
Dileep Bonthu, Bharath H.S., S. Bekinal, P. Jeyaraj, M. Doddamani
PurposeThe purpose of this study was to introduce three-dimensional printing (3DP) of functionally graded sandwich foams (FGSFs). This work was continued by predicting the mechanical buckling and free vibration behavior of 3DP FGSFs using experimental and numerical analyses.Design/methodology/approachInitially, hollow glass microballoon-reinforced high-density polyethylene-based polymer composite foams were developed, and these materials were extruded into their respective filaments. These filaments are used as feedstock materials in fused filament fabrication based 3DP for the development of FGSFs. Scanning electron microscopy analysis was performed on the freeze-dried samples to observe filler sustainability. Furthermore, the density, critical buckling load (Pcr), natural frequency (fn) and damping factor of FGSFs were evaluated. The critical buckling load (Pcr) of the FGSFs was estimated using the double-tangent method and modified Budiansky criteria.FindingsThe density of FGSFs decreased with increasing filler percentage. The mechanical buckling load increased with the filler percentage. The natural frequency corresponding to the first mode of the FGSFs exhibited a decreasing trend with an increasing load in the pre-buckling regime and an increase in post-buckled zone, whereas the damping factor exhibited the opposite trend.Originality/valueThe current research work is valuable for the area of 3D printing by developing the functionally graded foam based sandwich beams. Furthermore, it intended to present the buckling behavior of 3D printed FGSFs, variation of frequency and damping factor corresponding to first three modes with increase in load.
目的介绍功能梯度夹层泡沫(FGSF)的三维打印技术。这项工作是通过使用实验和数值分析预测3DP-FGSF的机械屈曲和自由振动行为来继续的。设计/方法/方法最初,开发了中空玻璃微球增强高密度聚乙烯基聚合物复合泡沫,并将这些材料挤出成各自的细丝。这些细丝被用作基于3DP的熔融细丝制造中的原料,用于开发FGSF。对冷冻干燥的样品进行扫描电子显微镜分析,以观察填料的可持续性。此外,还对FGSF的密度、临界屈曲载荷(Pcr)、固有频率(fn)和阻尼因子进行了评估。使用双切线法和修正的Budiansky准则估计了FGSF的临界屈曲载荷(Pcr)。结果FGSF的密度随着填料比例的增加而降低。机械屈曲载荷随填料百分比的增加而增加。对应于FGSF第一模式的固有频率在预屈曲状态下随着载荷的增加和后屈曲区域的增加而呈现出下降趋势,而阻尼因子呈现出相反的趋势。独创性/价值当前的研究工作通过开发功能梯度泡沫基夹层梁在3D打印领域具有价值。此外,它旨在呈现3D打印的FGSF的屈曲行为,对应于前三种模式的频率和阻尼因子随载荷增加的变化。
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引用次数: 0
A novel optimization framework for minimizing the surface roughness while increasing the material processing rate in the SLM process of 316L stainless steel 在316L不锈钢的SLM工艺中,一种最小化表面粗糙度同时提高材料加工率的新型优化框架
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-09-01 DOI: 10.1108/rpj-11-2022-0390
I. La Fé-Perdomo, J. Ramos-Grez, Ramon Quiza, Ignacio Jeria, C. Guerra
Purpose316 L stainless steel alloy is potentially the most used material in the selective laser melting (SLM) process because of its versatility and broad fields of applications (e.g. medical devices, tooling, automotive, etc.). That is why producing fully functional parts through optimal printing configuration is still a key issue to be addressed. This paper aims to present an entirely new framework for simultaneously reducing surface roughness (SR) while increasing the material processing rate in the SLM process of 316L stainless steel, keeping fundamental mechanical properties within their allowable range.Design/methodology/approachConsidering the nonlinear relationship between the printing parameters and features analyzed in the entire experimental space, machine learning and statistical modeling methods were defined to describe the behavior of the selected variables in the as-built conditions. First, the Box–Behnken design was adopted and corresponding experimental planning was conducted to measure the required variables. Second, the relationship between the laser power, scanning speed, hatch distance, layer thickness and selected responses was modeled using empirical methods. Subsequently, three heuristic algorithms (nonsorting genetic algorithm, multi-objective particle swarm optimization and cross-entropy method) were used and compared to search for the Pareto solutions of the formulated multi-objective problem.FindingsA minimum SR value of approximately 12.83 μm and a maximum material processing rate of 2.35 mm3/s were achieved. Finally, some verification experiments recommended by the decision-making system implemented strongly confirmed the reliability of the proposed optimization methodology by providing the ultimate part qualities and their mechanical properties nearly identical to those defined in the literature, with only approximately 10% of error at the maximum.Originality/valueTo the best of the authors’ knowledge, this is the first study dealing with an entirely different and more comprehensive approach for optimizing the 316 L SLM process, embedding it in a unique framework of mechanical and surface properties and material processing rate.
316l不锈钢合金由于其通用性和广泛的应用领域(如医疗设备、工具、汽车等),可能是选择性激光熔化(SLM)工艺中使用最多的材料。这就是为什么通过最佳的打印配置来生产功能齐全的部件仍然是一个需要解决的关键问题。本文旨在提出一种全新的框架,在316L不锈钢的SLM工艺中,在降低表面粗糙度(SR)的同时提高材料的加工速度,使基本力学性能保持在允许范围内。设计/方法/方法考虑到整个实验空间中所分析的打印参数与特征之间的非线性关系,定义了机器学习和统计建模方法来描述所选变量在建成条件下的行为。首先,采用Box-Behnken设计,并进行相应的实验规划,测量所需变量。其次,利用经验方法对激光功率、扫描速度、舱口距离、层厚与所选响应之间的关系进行建模。随后,采用非排序遗传算法、多目标粒子群优化算法和交叉熵法三种启发式算法进行比较,搜索公式化多目标问题的Pareto解。结果表明,该材料的最小SR值约为12.83 μm,最大加工速率为2.35 mm3/s。最后,决策系统推荐的一些验证实验强有力地证实了所提出的优化方法的可靠性,提供的最终零件质量和力学性能与文献中定义的几乎相同,最大误差仅约为10%。原创性/价值据作者所知,这是第一个采用完全不同的、更全面的方法来优化316 L SLM工艺的研究,将其嵌入到机械、表面性能和材料加工速度的独特框架中。
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引用次数: 0
Study of parametric interaction during fused filament fabrication (FFF) using interpretive structural modelling (ISM) followed by experimental analysis 利用解释结构模型(ISM)对熔丝制造过程中的参数相互作用进行了研究,并进行了实验分析
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-08-28 DOI: 10.1108/rpj-03-2023-0092
Shekhar Sharma, S. Datta, Tarapada Roy, S. Mahapatra
PurposeFused filament fabrication (FFF) is a type of additive manufacturing (AM) based on materials extrusion. It is the most widely practiced AM route, especially used for polymer-based rapid prototyping and customized product fabrication in relation to aerospace, automotive, architecture, consumer goods and medical applications. During FFF, part quality (surface finish, dimensional accuracy and static mechanical strength) is greatly influenced by several process parameters. The paper aims to study FFF parametric influence on aforesaid part quality aspects. In addition, dynamic analysis of the FFF part is carried out.Design/methodology/approachInterpretive structural modelling is attempted to articulate interrelationships that exist amongst FFF parameters. Next, a few specimens are fabricated using acrylonitrile butadiene styrene plastic at varied build orientation and build style. Effects of build orientation and build style on part’s ultimate tensile strength, flexure strength along with width build time are studied. Prototype beams (of different thickness) are fabricated by varying build style. Instrumental impact hammer Modal analysis is performed on the cantilever beams (cantilever support) to obtain the natural frequencies (first mode). Parametric influence on natural frequencies is also studied.FindingsStatic mechanical properties (tensile and flexure strength) are greatly influenced by build style and build orientation. Natural frequency (NF) of prototype beams is highly influenced by the build style and beam thickness.Originality/valueFFF built parts when subjected to application, may have to face a variety of external dynamic loads. If frequency of induced vibration (due to external force) matches with NF of the component part, resonance is incurred. To avoid occurrence of resonance, operational frequency (frequency of externally applied forces) must be lower/ higher than the NF. Because NF depends on mass and stiffness, and boundary conditions, FFF parts produced through varying build style may definitely correspond to varied NF. This aspect is explained in this work.
目的熔丝制造(FFF)是一种基于材料挤压的增材制造(AM)。这是最广泛实践的增材制造路线,特别是用于与航空航天,汽车,建筑,消费品和医疗应用相关的基于聚合物的快速原型和定制产品制造。在FFF过程中,零件质量(表面光洁度、尺寸精度和静态机械强度)受几个工艺参数的影响很大。本文旨在研究FFF参数对上述零件质量方面的影响。此外,还对FFF部分进行了动态分析。设计/方法/方法解释性结构建模试图阐明FFF参数之间存在的相互关系。接下来,使用丙烯腈-丁二烯-苯乙烯塑料在不同的建造方向和建造风格制作一些标本。研究了构件的搭接方向和搭接方式对构件极限抗拉强度和抗弯强度随宽度搭接时间的影响。原型梁(不同厚度)是由不同的建造风格制造的。对悬臂梁(悬臂支承)进行仪器冲击锤模态分析,得到其固有频率(第一模态)。还研究了参数对固有频率的影响。静态力学性能(拉伸和弯曲强度)受构造样式和构造方向的影响很大。原型梁的固有频率受结构形式和梁厚的影响较大。原创性/价值性造件在受到应用时,可能要面对各种外部动态载荷。如果感应振动(由外力引起)的频率与构件的NF相匹配,则产生共振。为避免发生共振,工作频率(外力频率)必须低于/高于NF。由于NF取决于质量和刚度以及边界条件,因此通过不同的建造方式生产的FFF部件肯定对应于不同的NF。本文对这方面进行了阐述。
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引用次数: 0
Flexible and multi-material intrinsically conductive polymer devices fabricated via DLP and DIW additive manufacturing techniques 通过DLP和DIW增材制造技术制造的柔性和多材料本质导电聚合物器件
IF 3.9 4区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2023-08-24 DOI: 10.1108/rpj-02-2023-0037
K. Engel, P. Kilmartin, O. Diegel
PurposeThe purpose of this study is to explore the synthesis of novel conductive photo-resins to produce flexible conducting composites for use in additive manufacturing. By using direct ink writing (DIW) additive manufacturing, this study aims to explore the fabrication of multimaterial devices with conductive and insulating components. Using digital light processing (DLP) additive manufacturing, this study aims to fabricate detailed objects with higher resolution than material extrusion 3D printing systems.Design/methodology/approachIn this paper, several photocurable conducting resins were prepared for DIW and DLP additive manufacturing. These resins were then cured using 405 nm near UV light to create intrinsically conductive polymer (ICP) composites. The electrochemical properties of these composites were analysed, and the effect of co-monomer choice and crosslinking density was determined. These results determined a suitable resin for subsequent additive manufacture using DIW and DLP. These 3D printing techniques were used to develop flexible conducting devices of submillimetre resolution that were fabricated with unmodified, commercially available 3D printers.FindingsCyclic voltammetry and volume conductivity analysis of the conducting resins determined the most conductive resin formula for 3D printing. Conductive devices were fabricated using the two 3D printing techniques. A multimaterial soft conducting device was fabricated using DIW, and each conducting component was insulated from its neighbours. DLP was used to fabricate a soft conducting device with good XY resolution with a minimum feature size of 0.2 mm. All devices were prepared in unmodified commercially available 3D printers.Practical implicationsThese findings have value in the development of soft robotics, artificial muscles and wearable sensors. In addition, this work highlights techniques for DIW and DLP additive manufacturing.Originality/valueSeveral original conducting resin formulae were developed for use in two 3D printing systems. The resulting 3D-printed composites are soft and flexible while maintaining their conductive properties. These findings are of value to both polymer chemists and to the field of additive manufacturing.
目的探索新型导电光树脂的合成方法,制备可用于增材制造的柔性导电复合材料。本研究旨在利用直接墨水书写(DIW)增材制造技术,探索具有导电和绝缘元件的多材料器件的制造方法。利用数字光处理(DLP)增材制造,本研究旨在以比材料挤压3D打印系统更高的分辨率制造详细的物体。设计/方法/方法本文制备了几种用于DIW和DLP增材制造的光固化导电树脂。然后使用405 nm的近紫外光固化这些树脂,以创建本质导电聚合物(ICP)复合材料。分析了复合材料的电化学性能,确定了共聚物选择和交联密度对复合材料性能的影响。这些结果确定了随后使用DIW和DLP进行增材制造的合适树脂。这些3D打印技术被用于开发亚毫米分辨率的柔性导电装置,这些装置是用未经修改的商用3D打印机制造的。通过对导电树脂的循环伏安法和体积电导率分析,确定了最适合3D打印的导电树脂配方。导电器件是使用这两种3D打印技术制造的。采用DIW技术制备了一种多材料软导电器件,各导电元件之间相互绝缘。利用DLP制备了具有良好XY分辨率的软导电器件,最小特征尺寸为0.2 mm。所有设备都是在未经修改的商用3D打印机上制备的。这些发现对软机器人、人造肌肉和可穿戴传感器的发展具有重要价值。此外,本工作重点介绍了DIW和DLP增材制造技术。几个原创的导电树脂配方被开发用于两个3D打印系统。由此产生的3d打印复合材料柔软柔韧,同时保持其导电性能。这些发现对聚合物化学家和增材制造领域都有价值。
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引用次数: 0
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Rapid Prototyping Journal
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