Pub Date : 2023-08-03DOI: 10.1108/rpj-04-2023-0136
Abdul Wahab Hashmi, H. Mali, Anoj Meena, Shadab Ahmad, Yebing Tian
Purpose Three-dimensional (3D) printed parts usually have poor surface quality due to layer manufacturing’s “stair casing/stair-stepping”. So post-processing is typically needed to enhance its capabilities to be used in closed tolerance applications. This study aims to examine abrasive flow finishing for 3D printed polylactic acid (PLA) parts. Design/methodology/approach A new eco-friendly abrasive flow machining media (EFAFM) was developed, using paper pulp as a base material, waste vegetable oil as a liquid synthesizer and natural additives such as glycine to finish 3D printed parts. Characterization of the media was conducted through thermogravimetric analysis and Fourier transform infrared spectroscopy. PLA crescent prism parts were produced via fused deposition modelling (FDM) and finished using AFM, with experiments designed using central composite design (CCD). The impact of process parameters, including media viscosity, extrusion pressure, layer thickness and finishing time, on percentage improvement in surface roughness (%ΔRa) and material removal rate were analysed. Artificial neural network (ANN) and improved grey wolf optimizer (IGWO) were used for data modelling and optimization, respectively. Findings The abrasive media developed was effective for finishing FDM printed parts using AFM, with SEM images and 3D surface profile showing a significant improvement in surface topography. Optimal solutions were obtained using the ANN-IGWO approach. EFAFM was found to be a promising method for improving finishing quality on FDM 3D printed parts. Research limitations/implications The present study is focused on finishing FDM printed crescent prism parts using AFM. Future research may be done on more complex shapes and could explore the impact of different materials, such as thermoplastics and composites for different applications. Also, implication of other techniques, such as chemical vapour smoothing, mechanical polishing may be explored. Practical implications In the biomedical field, the use of 3D printing has revolutionized the way in which medical devices, implants and prosthetics are designed and manufactured. The biodegradable and biocompatible properties of PLA make it an ideal material for use in biomedical applications, such as the fabrication of surgical guides, dental models and tissue engineering scaffolds. The ability to finish PLA 3D printed parts using AFM can improve their biocompatibility, making them more suitable for use in the human body. The improved surface quality of 3D printed parts can also facilitate their sterilization, which is critical in the biomedical field. Social implications The use of eco-friendly abrasive flow finishing for 3D printed parts can have a positive impact on the environment by reducing waste and promoting sustainable manufacturing practices. Additionally, it can improve the quality and functionality of 3D printed products, leading to better performance and longer lifespans. This can
{"title":"A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN","authors":"Abdul Wahab Hashmi, H. Mali, Anoj Meena, Shadab Ahmad, Yebing Tian","doi":"10.1108/rpj-04-2023-0136","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0136","url":null,"abstract":"\u0000Purpose\u0000Three-dimensional (3D) printed parts usually have poor surface quality due to layer manufacturing’s “stair casing/stair-stepping”. So post-processing is typically needed to enhance its capabilities to be used in closed tolerance applications. This study aims to examine abrasive flow finishing for 3D printed polylactic acid (PLA) parts.\u0000\u0000\u0000Design/methodology/approach\u0000A new eco-friendly abrasive flow machining media (EFAFM) was developed, using paper pulp as a base material, waste vegetable oil as a liquid synthesizer and natural additives such as glycine to finish 3D printed parts. Characterization of the media was conducted through thermogravimetric analysis and Fourier transform infrared spectroscopy. PLA crescent prism parts were produced via fused deposition modelling (FDM) and finished using AFM, with experiments designed using central composite design (CCD). The impact of process parameters, including media viscosity, extrusion pressure, layer thickness and finishing time, on percentage improvement in surface roughness (%ΔRa) and material removal rate were analysed. Artificial neural network (ANN) and improved grey wolf optimizer (IGWO) were used for data modelling and optimization, respectively.\u0000\u0000\u0000Findings\u0000The abrasive media developed was effective for finishing FDM printed parts using AFM, with SEM images and 3D surface profile showing a significant improvement in surface topography. Optimal solutions were obtained using the ANN-IGWO approach. EFAFM was found to be a promising method for improving finishing quality on FDM 3D printed parts.\u0000\u0000\u0000Research limitations/implications\u0000The present study is focused on finishing FDM printed crescent prism parts using AFM. Future research may be done on more complex shapes and could explore the impact of different materials, such as thermoplastics and composites for different applications. Also, implication of other techniques, such as chemical vapour smoothing, mechanical polishing may be explored.\u0000\u0000\u0000Practical implications\u0000In the biomedical field, the use of 3D printing has revolutionized the way in which medical devices, implants and prosthetics are designed and manufactured. The biodegradable and biocompatible properties of PLA make it an ideal material for use in biomedical applications, such as the fabrication of surgical guides, dental models and tissue engineering scaffolds. The ability to finish PLA 3D printed parts using AFM can improve their biocompatibility, making them more suitable for use in the human body. The improved surface quality of 3D printed parts can also facilitate their sterilization, which is critical in the biomedical field.\u0000\u0000\u0000Social implications\u0000The use of eco-friendly abrasive flow finishing for 3D printed parts can have a positive impact on the environment by reducing waste and promoting sustainable manufacturing practices. Additionally, it can improve the quality and functionality of 3D printed products, leading to better performance and longer lifespans. This can ","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-08-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41947749","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Purpose The purpose of this study is to increasing the gauge factor, reducing the hysteresis error and improving the stability over cyclic deformations of a conductive polylactic acid (CPLA)-based 3D-printed strain sensor by modifying the sensing element geometry. Design/methodology/approach Five different configurations, namely, linear, serpentine, square, triangular and trapezoidal, of CPLA sensing elements are printed on the thermoplastic polyurethane substrate material individually. The resistance change ratio of the printed sensors, when loaded to a predefined percentage of the maximum strain values over multiple cycles, is recorded. Finally, the thickness of substrate and CPLA and the included angle of the triangular strain sensor are evaluated for their influences on the sensitivity. Findings The triangular configuration yields the least hysteresis error with high accuracy over repeated loading conditions, because of its uniform stress distribution, whereas the conventional linear configuration produces the maximum sensitivity with low accuracy. The thickness of the substrate and sensing element has more influence over the included angle, in enhancing the sensitivity of the triangular configuration. The sensitivity of the triangular configuration exceeds the linear configuration when printed at ideal sensor dimensional values. Research limitations/implications The 3D printing parameters are kept constant for all the configurations; rather it can be varied for improving the performance of the sensor. Furthermore, the influences of stretching rate and nozzle temperature of the sensing material are not considered in this work. Originality/value The sensitivity and accuracy of CPLA-based strain sensor are evaluated for modification in its geometry, and the performance metrics are enhanced using the regression modelling.
{"title":"Sensitivity enhancement through geometry modification of 3D printed conductive PLA-based strain sensors","authors":"Dhinesh S.K., Senthil Kumar Kallippatti Lakshmanan","doi":"10.1108/rpj-02-2023-0069","DOIUrl":"https://doi.org/10.1108/rpj-02-2023-0069","url":null,"abstract":"\u0000Purpose\u0000The purpose of this study is to increasing the gauge factor, reducing the hysteresis error and improving the stability over cyclic deformations of a conductive polylactic acid (CPLA)-based 3D-printed strain sensor by modifying the sensing element geometry.\u0000\u0000\u0000Design/methodology/approach\u0000Five different configurations, namely, linear, serpentine, square, triangular and trapezoidal, of CPLA sensing elements are printed on the thermoplastic polyurethane substrate material individually. The resistance change ratio of the printed sensors, when loaded to a predefined percentage of the maximum strain values over multiple cycles, is recorded. Finally, the thickness of substrate and CPLA and the included angle of the triangular strain sensor are evaluated for their influences on the sensitivity.\u0000\u0000\u0000Findings\u0000The triangular configuration yields the least hysteresis error with high accuracy over repeated loading conditions, because of its uniform stress distribution, whereas the conventional linear configuration produces the maximum sensitivity with low accuracy. The thickness of the substrate and sensing element has more influence over the included angle, in enhancing the sensitivity of the triangular configuration. The sensitivity of the triangular configuration exceeds the linear configuration when printed at ideal sensor dimensional values.\u0000\u0000\u0000Research limitations/implications\u0000The 3D printing parameters are kept constant for all the configurations; rather it can be varied for improving the performance of the sensor. Furthermore, the influences of stretching rate and nozzle temperature of the sensing material are not considered in this work.\u0000\u0000\u0000Originality/value\u0000The sensitivity and accuracy of CPLA-based strain sensor are evaluated for modification in its geometry, and the performance metrics are enhanced using the regression modelling.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49405204","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-31DOI: 10.1108/rpj-03-2023-0082
N. Chikkanna, S. Krishnapillai, Velmurugan Ramachandran
Purpose Auxetics are the class of cellular materials with a negative Poisson’s ratio. This paper aims to study the low-cost 3D printing capabilities and printing variations and improve the indentation performance of the re-entrant diamond auxetic metamaterial by tuning the structural parameters that have not been reported. Design/methodology/approach The design of experiment strategy was adopted to study the influence of re-entrant angle, diamond angle and thickness-to-length ratio on relative density, load, stiffness and specific energy absorption (SEA) during indentation experimentally. Grey relational analysis was chosen as a multi-objective optimisation technique to optimise structural performance. Surrogate models were proposed to uphold the metamaterial’s tailorability for desired application needs. The fit and efficacy of the proposed models were tested using specific statistical techniques. The predominant deformation mechanisms observed with the alteration in structural parameters were discussed. Findings The improvements noticed are 48 times hike in load, 112 times improvement in stiffness and 10 times increase in SEA for optimised structures. The surrogate models are proven to predict the outputs accurately for new input parameters. In-situ displacement fields are visualised with an image processing technique. Originality/value To the best of the authors’ knowledge, the indentation performance of the re-entrant diamond auxetic metamaterials has not been reported and reported for the first time. The influence of geometrical parameters on the newly developed structure under concentrated loading was evaluated. The geometry-dependent printing variations associated with 3D printing have been discussed to help the user to fabricate re-entrant diamond auxetic metamaterial.
{"title":"Investigation on the indentation performance of 3D printed re-entrant diamond auxetic metamaterial: printability and tailorability for futuristic applications","authors":"N. Chikkanna, S. Krishnapillai, Velmurugan Ramachandran","doi":"10.1108/rpj-03-2023-0082","DOIUrl":"https://doi.org/10.1108/rpj-03-2023-0082","url":null,"abstract":"\u0000Purpose\u0000Auxetics are the class of cellular materials with a negative Poisson’s ratio. This paper aims to study the low-cost 3D printing capabilities and printing variations and improve the indentation performance of the re-entrant diamond auxetic metamaterial by tuning the structural parameters that have not been reported.\u0000\u0000\u0000Design/methodology/approach\u0000The design of experiment strategy was adopted to study the influence of re-entrant angle, diamond angle and thickness-to-length ratio on relative density, load, stiffness and specific energy absorption (SEA) during indentation experimentally. Grey relational analysis was chosen as a multi-objective optimisation technique to optimise structural performance. Surrogate models were proposed to uphold the metamaterial’s tailorability for desired application needs. The fit and efficacy of the proposed models were tested using specific statistical techniques. The predominant deformation mechanisms observed with the alteration in structural parameters were discussed.\u0000\u0000\u0000Findings\u0000The improvements noticed are 48 times hike in load, 112 times improvement in stiffness and 10 times increase in SEA for optimised structures. The surrogate models are proven to predict the outputs accurately for new input parameters. In-situ displacement fields are visualised with an image processing technique.\u0000\u0000\u0000Originality/value\u0000To the best of the authors’ knowledge, the indentation performance of the re-entrant diamond auxetic metamaterials has not been reported and reported for the first time. The influence of geometrical parameters on the newly developed structure under concentrated loading was evaluated. The geometry-dependent printing variations associated with 3D printing have been discussed to help the user to fabricate re-entrant diamond auxetic metamaterial.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42523189","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-31DOI: 10.1108/rpj-02-2023-0044
Iniya Dinakaran, Chowdhury Sakib-Uz-Zaman, Arafater Rahman, M. A. H. Khondoker
Purpose This paper aims to understand the effect of extrusion conditions on the degree of foaming of polylactic acid (PLA) during three-dimensional (3D) printing. It was also targeted to optimize the slicing parameters for 3D printing and to study how the properties of printed parts are influenced by the extrusion conditions. Design/methodology/approach This study used a commercially available PLA filament that undergoes chemical foaming. An extrusion 3D printer was used to produce individual extrudates and print samples that were characterized using an optical microscope, scanning electron microscope and custom in-house apparatuses. Findings The degree of foaming of the extrudates was found to strongly depend on the extrusion temperature and the material feed speed. Higher temperatures significantly increased the number of nucleation sites for the blowing agent as well as the growth rate of micropores. Also, as the material feed speed increased, the micropores were allowed to grow bigger which resulted in higher degrees of foaming. It was also found that, as the degree of foaming increased, the porous parts printed with optimized slicing parameters were lightweight and thermally less conductive. Originality/value This study fills the gap in literature where it examines the foaming behavior of individual extrudates as they are extruded. By doing so, this work distinguishes the effect of extrusion conditions from the effect of slicing parameters on the foaming behavior which enhances the understanding of extrusion of chemically foamed PLA.
{"title":"Controlling degree of foaming in extrusion 3D printing of porous polylactic acid","authors":"Iniya Dinakaran, Chowdhury Sakib-Uz-Zaman, Arafater Rahman, M. A. H. Khondoker","doi":"10.1108/rpj-02-2023-0044","DOIUrl":"https://doi.org/10.1108/rpj-02-2023-0044","url":null,"abstract":"\u0000Purpose\u0000This paper aims to understand the effect of extrusion conditions on the degree of foaming of polylactic acid (PLA) during three-dimensional (3D) printing. It was also targeted to optimize the slicing parameters for 3D printing and to study how the properties of printed parts are influenced by the extrusion conditions.\u0000\u0000\u0000Design/methodology/approach\u0000This study used a commercially available PLA filament that undergoes chemical foaming. An extrusion 3D printer was used to produce individual extrudates and print samples that were characterized using an optical microscope, scanning electron microscope and custom in-house apparatuses.\u0000\u0000\u0000Findings\u0000The degree of foaming of the extrudates was found to strongly depend on the extrusion temperature and the material feed speed. Higher temperatures significantly increased the number of nucleation sites for the blowing agent as well as the growth rate of micropores. Also, as the material feed speed increased, the micropores were allowed to grow bigger which resulted in higher degrees of foaming. It was also found that, as the degree of foaming increased, the porous parts printed with optimized slicing parameters were lightweight and thermally less conductive.\u0000\u0000\u0000Originality/value\u0000This study fills the gap in literature where it examines the foaming behavior of individual extrudates as they are extruded. By doing so, this work distinguishes the effect of extrusion conditions from the effect of slicing parameters on the foaming behavior which enhances the understanding of extrusion of chemically foamed PLA.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46679200","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-31DOI: 10.1108/rpj-01-2023-0032
S. Srivastava, R. K. Garg, A. Sachdeva, Vishal S. Sharma, Sehijpal Singh, M. Gupta
Purpose Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process. Design/methodology/approach The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS. Findings A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively. Originality/value To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.
{"title":"Distribution of temperature and residual stresses in GMA-DED based wire-arc additive manufacturing","authors":"S. Srivastava, R. K. Garg, A. Sachdeva, Vishal S. Sharma, Sehijpal Singh, M. Gupta","doi":"10.1108/rpj-01-2023-0032","DOIUrl":"https://doi.org/10.1108/rpj-01-2023-0032","url":null,"abstract":"\u0000Purpose\u0000Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process.\u0000\u0000\u0000Design/methodology/approach\u0000The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS.\u0000\u0000\u0000Findings\u0000A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively.\u0000\u0000\u0000Originality/value\u0000To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44133402","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-26DOI: 10.1108/rpj-10-2022-0371
J. Mercado-Colmenero, M. L. La Rubia, Elena Mata-García, Moisés Rodriguez-Santiago, Cristina Martín-Doñate
Purpose Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs. Design/methodology/approach In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests. Findings As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations. Practical implications The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs. Originality/value Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.
{"title":"Using numerical-experimental analysis to evaluate rPET mechanical behavior under compressive stresses and MEX additive manufacturing for new sustainable designs","authors":"J. Mercado-Colmenero, M. L. La Rubia, Elena Mata-García, Moisés Rodriguez-Santiago, Cristina Martín-Doñate","doi":"10.1108/rpj-10-2022-0371","DOIUrl":"https://doi.org/10.1108/rpj-10-2022-0371","url":null,"abstract":"\u0000Purpose\u0000Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs.\u0000\u0000\u0000Design/methodology/approach\u0000In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests.\u0000\u0000\u0000Findings\u0000As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations.\u0000\u0000\u0000Practical implications\u0000The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs.\u0000\u0000\u0000Originality/value\u0000Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42991868","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-18DOI: 10.1108/rpj-03-2023-0087
P. Sukontasukkul, Buchit Maho, Sila Komkham, Satharat Pianfuengfoo, Hexin Zhang, Dooyeol Yoo, Weerachart Tangchirapat, Worathep Sae-Long, S. Limkatanyu, P. Chindaprasirt
Purpose This study aims to propose a technique that establishes a mathematical relationship between width and time, and utilizes a derivative method to determine the initial printable time (tint) for mortar suitable for 3D printing. The study conducted experimental tests on the tint, layer strain, and the relationship between filament width and time. These tests involved plain mortar and mortar reinforced with micro-fibers at varying volume fractions. The tint was determined analytically using the derivative method. Design/methodology/approach This study introduces a technique to accurately determine the initial printable time (tint) and width/height of printed cement mortar. Precise tint determination is essential for ensuring proper filament printing timing and eliminating the need for trial and error. Findings Results show that the proposed technique accurately determines the tint, as evidenced by the resemblance between expected and actual initial widths. Fiber-reinforced mortar (FRM) has a smaller tint than plain mortar, which decreases with an increasing fiber content. Additionally, FRM displays smaller layer strains compared to plain mortar. Research limitations/implications Results show that the proposed technique accurately determines the tint, as evidenced by the resemblance between expected and actual initial widths. FRM exhibits smaller tint and displays smaller layer strains than plain mortar. Originality/value This study introduces a novel technique that uses a mathematical relationship to determine the tint and height of cement mortar printing.
{"title":"Precise determination of initial printable time for cement mortar 3D printing using a derivative method","authors":"P. Sukontasukkul, Buchit Maho, Sila Komkham, Satharat Pianfuengfoo, Hexin Zhang, Dooyeol Yoo, Weerachart Tangchirapat, Worathep Sae-Long, S. Limkatanyu, P. Chindaprasirt","doi":"10.1108/rpj-03-2023-0087","DOIUrl":"https://doi.org/10.1108/rpj-03-2023-0087","url":null,"abstract":"\u0000Purpose\u0000This study aims to propose a technique that establishes a mathematical relationship between width and time, and utilizes a derivative method to determine the initial printable time (tint) for mortar suitable for 3D printing. The study conducted experimental tests on the tint, layer strain, and the relationship between filament width and time. These tests involved plain mortar and mortar reinforced with micro-fibers at varying volume fractions. The tint was determined analytically using the derivative method.\u0000\u0000\u0000Design/methodology/approach\u0000This study introduces a technique to accurately determine the initial printable time (tint) and width/height of printed cement mortar. Precise tint determination is essential for ensuring proper filament printing timing and eliminating the need for trial and error.\u0000\u0000\u0000Findings\u0000Results show that the proposed technique accurately determines the tint, as evidenced by the resemblance between expected and actual initial widths. Fiber-reinforced mortar (FRM) has a smaller tint than plain mortar, which decreases with an increasing fiber content. Additionally, FRM displays smaller layer strains compared to plain mortar.\u0000\u0000\u0000Research limitations/implications\u0000Results show that the proposed technique accurately determines the tint, as evidenced by the resemblance between expected and actual initial widths. FRM exhibits smaller tint and displays smaller layer strains than plain mortar.\u0000\u0000\u0000Originality/value\u0000This study introduces a novel technique that uses a mathematical relationship to determine the tint and height of cement mortar printing.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49492761","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-17DOI: 10.1108/rpj-10-2022-0358
Kazi Moshiur Rahman, H. Miyanaji, C. Williams
Purpose In binder jetting, the interaction between the liquid binder droplets and the powder particles defines the shape of the printed primitives. The purpose of this study is to explore the interaction of the relative size of powder particles and binder droplets and the subsequent effects on macro-scale part properties. Design/methodology/approach The effects of different particle size distribution (5–25 µm and 15–45 µm) of stainless steel 316 L powders and droplet sizes (10 and 30 pL) on part density, shrinkage, mechanical strength, pore morphology and distribution are investigated. Experimental samples were fabricated in two different layer thicknesses (50 and 100 µm). Findings While 15–45 µm samples demonstrated higher green density (53.10 ± 0.25%) than 5–25 µm samples (50.31 ± 1.06%), higher sintered densities were achieved in 5–25 µm samples (70.60 ± 6.18%) compared to 15–45 µm samples (65.23 ± 3.24%). Samples of 5–25 µm also demonstrated superior ultimate tensile strength (94.66 ± 25.92 MPa) compared to 15–45 µm samples (39.34 ± 7.33 MPa). Droplet size effects were found to be negligible on both green and sintered densities; however, specimens printed with 10-pL droplets had higher ultimate tensile strength (79.70 ± 42.31 MPa) compared to those made from 30-pL droplets (54.29 ± 23.35 MPa). Originality/value To the best of the authors’ knowledge, this paper details the first report of the combined effects of different particle size distribution with different binder droplet sizes on the part macro-scale properties. The results can inform appropriate process parameters to achieve desired final part properties.
{"title":"Effects of binder droplet size and powder particle size on binder jetting part properties","authors":"Kazi Moshiur Rahman, H. Miyanaji, C. Williams","doi":"10.1108/rpj-10-2022-0358","DOIUrl":"https://doi.org/10.1108/rpj-10-2022-0358","url":null,"abstract":"\u0000Purpose\u0000In binder jetting, the interaction between the liquid binder droplets and the powder particles defines the shape of the printed primitives. The purpose of this study is to explore the interaction of the relative size of powder particles and binder droplets and the subsequent effects on macro-scale part properties.\u0000\u0000\u0000Design/methodology/approach\u0000The effects of different particle size distribution (5–25 µm and 15–45 µm) of stainless steel 316 L powders and droplet sizes (10 and 30 pL) on part density, shrinkage, mechanical strength, pore morphology and distribution are investigated. Experimental samples were fabricated in two different layer thicknesses (50 and 100 µm).\u0000\u0000\u0000Findings\u0000While 15–45 µm samples demonstrated higher green density (53.10 ± 0.25%) than 5–25 µm samples (50.31 ± 1.06%), higher sintered densities were achieved in 5–25 µm samples (70.60 ± 6.18%) compared to 15–45 µm samples (65.23 ± 3.24%). Samples of 5–25 µm also demonstrated superior ultimate tensile strength (94.66 ± 25.92 MPa) compared to 15–45 µm samples (39.34 ± 7.33 MPa). Droplet size effects were found to be negligible on both green and sintered densities; however, specimens printed with 10-pL droplets had higher ultimate tensile strength (79.70 ± 42.31 MPa) compared to those made from 30-pL droplets (54.29 ± 23.35 MPa).\u0000\u0000\u0000Originality/value\u0000To the best of the authors’ knowledge, this paper details the first report of the combined effects of different particle size distribution with different binder droplet sizes on the part macro-scale properties. The results can inform appropriate process parameters to achieve desired final part properties.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49423646","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-17DOI: 10.1108/rpj-04-2023-0121
F. Touchard, D. Marchand, L. Chocinski-Arnault, T. Fournier, C. Magro
Purpose Additive manufacturing is a recent technology used in the production of composite materials. The use of continuous fibres as reinforcement is necessary to achieve high mechanical performance. However, making these materials more environmentally friendly is still challenging. The purpose of this study was to investigate the feasibility of 3D printing a composite made of continuous regenerated cellulose fibres using a standard 3D printer generally used for printing polymers. Design/methodology/approach The production process was based on a pre-impregnated filament made from a tape containing continuous cellulose fibres and Pebax® matrix. 3D printed composite samples were fabricated using fused deposition modelling. The tape, filament and 3D printed composites were first analysed by means of modulated differential scanning calorimetry and micrography. Tensile tests were then performed, and the mechanical characteristics were determined at each step of the production process. Fracture surfaces were investigated by field-emission gun–scanning electron microscopy. Findings Results showed that the mechanical behaviour of the material was maintained throughout the production process, and the 3D printed biocomposites had a stiffness equivalent to that of traditionally manufactured continuous cellulose fibre composites. The obtained 3D printed composites showed an increase in strength value by a factor of 4 and in tensile modulus by a factor of 20 compared to those of unreinforced Pebax® polymer. Originality/value This paper demonstrates the feasibility of 3D printing composites based on continuous cellulose fibres, paving the way for new biocomposites made by additive manufacturing.
{"title":"3D printing of continuous cellulose fibre composites: microstructural and mechanical characterisation","authors":"F. Touchard, D. Marchand, L. Chocinski-Arnault, T. Fournier, C. Magro","doi":"10.1108/rpj-04-2023-0121","DOIUrl":"https://doi.org/10.1108/rpj-04-2023-0121","url":null,"abstract":"\u0000Purpose\u0000Additive manufacturing is a recent technology used in the production of composite materials. The use of continuous fibres as reinforcement is necessary to achieve high mechanical performance. However, making these materials more environmentally friendly is still challenging. The purpose of this study was to investigate the feasibility of 3D printing a composite made of continuous regenerated cellulose fibres using a standard 3D printer generally used for printing polymers.\u0000\u0000\u0000Design/methodology/approach\u0000The production process was based on a pre-impregnated filament made from a tape containing continuous cellulose fibres and Pebax® matrix. 3D printed composite samples were fabricated using fused deposition modelling. The tape, filament and 3D printed composites were first analysed by means of modulated differential scanning calorimetry and micrography. Tensile tests were then performed, and the mechanical characteristics were determined at each step of the production process. Fracture surfaces were investigated by field-emission gun–scanning electron microscopy.\u0000\u0000\u0000Findings\u0000Results showed that the mechanical behaviour of the material was maintained throughout the production process, and the 3D printed biocomposites had a stiffness equivalent to that of traditionally manufactured continuous cellulose fibre composites. The obtained 3D printed composites showed an increase in strength value by a factor of 4 and in tensile modulus by a factor of 20 compared to those of unreinforced Pebax® polymer.\u0000\u0000\u0000Originality/value\u0000This paper demonstrates the feasibility of 3D printing composites based on continuous cellulose fibres, paving the way for new biocomposites made by additive manufacturing.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47061190","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-06-27DOI: 10.1108/rpj-07-2022-0247
Farid Salari, P. Bosetti, V. Sglavo
Purpose Particles bed binding by selective cement activation (SCA) method is a computer-aided manufacturing (CAM) technique used to produce cementitious elements. A computer-aided design file is sliced to generate G-codes before printing. This paper aims to study the effect of key input parameters for slicer software on the final properties of printed products. Design/methodology/approach The one factor at a time (OFAT) methodology is used to investigate the impact of selected parameters on the final properties of printed specimens, and the causes for the variations in outcomes of each variable are discussed. Findings Finer aggregates can generate a more compact layer, resulting in a denser product with higher strength. Fluid pressure is directly determined by voxel rate (rV); however, high pressures enable better fluid penetration control for fortified products; for extreme rVs, residual voids in the interfaces between successive layers and single-line primitives impair mechanical strength. It was understood that printhead movement along the orientation of the parts in the powder bed improved the mechanical properties. Originality/value The design of experiment (DOE) method assesses the influence of process parameters on various input printing variables at the same time. As the resources are limited, a fractional factorial plan is carried out on a subset of a full factorial design; hence, providing physical interpretation behind changes in each factor is difficult. OFAT aids in analyzing the effect of a change in one factor on output while all other parameters are kept constant. The results assist engineers in properly considering the influence of variable variations for future DOE designs.
{"title":"Effect of printing strategies on the properties of product in selective Sorel cement activation","authors":"Farid Salari, P. Bosetti, V. Sglavo","doi":"10.1108/rpj-07-2022-0247","DOIUrl":"https://doi.org/10.1108/rpj-07-2022-0247","url":null,"abstract":"\u0000Purpose\u0000Particles bed binding by selective cement activation (SCA) method is a computer-aided manufacturing (CAM) technique used to produce cementitious elements. A computer-aided design file is sliced to generate G-codes before printing. This paper aims to study the effect of key input parameters for slicer software on the final properties of printed products.\u0000\u0000\u0000Design/methodology/approach\u0000The one factor at a time (OFAT) methodology is used to investigate the impact of selected parameters on the final properties of printed specimens, and the causes for the variations in outcomes of each variable are discussed.\u0000\u0000\u0000Findings\u0000Finer aggregates can generate a more compact layer, resulting in a denser product with higher strength. Fluid pressure is directly determined by voxel rate (rV); however, high pressures enable better fluid penetration control for fortified products; for extreme rVs, residual voids in the interfaces between successive layers and single-line primitives impair mechanical strength. It was understood that printhead movement along the orientation of the parts in the powder bed improved the mechanical properties.\u0000\u0000\u0000Originality/value\u0000The design of experiment (DOE) method assesses the influence of process parameters on various input printing variables at the same time. As the resources are limited, a fractional factorial plan is carried out on a subset of a full factorial design; hence, providing physical interpretation behind changes in each factor is difficult. OFAT aids in analyzing the effect of a change in one factor on output while all other parameters are kept constant. The results assist engineers in properly considering the influence of variable variations for future DOE designs.\u0000","PeriodicalId":20981,"journal":{"name":"Rapid Prototyping Journal","volume":" ","pages":""},"PeriodicalIF":3.9,"publicationDate":"2023-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44255757","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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