Mohammad Aman Ullah Al Amin, Yiran Yang, Md Humaun Kobir, Lei Di
Selective laser sintering has become one of the most popular additive manufacturing technologies owing to its great capability of fabricating complex structures with reduced or even eliminated need for the support structure. Meanwhile, an average of 50% to 70% of the consumed powder materials is not directly used for part fabrication. To reduce material waste and enhance material usage efficiency, research studies have been conducted to facilitate the recycling and/or reusing of the waste powder in selective laser sintering. In this research, polyamide 12 powders are studied including virgin powder, waste powder, recycled powder, and mixed powder (with a 30% refresh rate) in terms of their microscopic morphology and material properties. In addition, the location of the powder sampled from the build chamber is also studied for its impact on the powder size and shape. Experimental results show that the average particle size does not change much in different samples, but the standard deviation increases in waste powder. Furthermore, the averaged ultimate tensile strength of test specimens fabricated with virgin powder is around 25% higher than specimens made with mixed powder (30% virgin powder and 70% recycled powder), showing a clear mechanical degradation.
{"title":"Experimental Study of Microscopic Morphology and Material Property for Recycled Polyamide 12 Powder in Selective Laser Sintering","authors":"Mohammad Aman Ullah Al Amin, Yiran Yang, Md Humaun Kobir, Lei Di","doi":"10.1115/msec2022-85618","DOIUrl":"https://doi.org/10.1115/msec2022-85618","url":null,"abstract":"\u0000 Selective laser sintering has become one of the most popular additive manufacturing technologies owing to its great capability of fabricating complex structures with reduced or even eliminated need for the support structure. Meanwhile, an average of 50% to 70% of the consumed powder materials is not directly used for part fabrication. To reduce material waste and enhance material usage efficiency, research studies have been conducted to facilitate the recycling and/or reusing of the waste powder in selective laser sintering. In this research, polyamide 12 powders are studied including virgin powder, waste powder, recycled powder, and mixed powder (with a 30% refresh rate) in terms of their microscopic morphology and material properties. In addition, the location of the powder sampled from the build chamber is also studied for its impact on the powder size and shape. Experimental results show that the average particle size does not change much in different samples, but the standard deviation increases in waste powder. Furthermore, the averaged ultimate tensile strength of test specimens fabricated with virgin powder is around 25% higher than specimens made with mixed powder (30% virgin powder and 70% recycled powder), showing a clear mechanical degradation.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"23 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75290282","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ajanta Saha, Sarath Gopalakrishnan, J. Waimin, S. Sedaghat, Ye Mi, N. Glassmaker, Mukkerem Cakmak, A. Shakouri, R. Rahimi, Muhammad A. Alam
Roll-to-Roll (R2R) process is well suited for manufacturing low cost, miniaturized, solid contact Ion-selective electrodes (ISEs) of potentiometric sensors to be used for continuous monitoring of various analytes in environmental, industrial, and health-care applications. It is presumed that the intrinsic thickness variability of the R2R process would limit the accuracy of the ISE-based sensors and would make them inferior to sensors fabricated by higher precision manufacturing processes. Instead, in this paper we propose to use the intrinsic variability of R2R process as a “resource” to achieve high-accuracy sensing even when the sensors are operated in uncontrolled field conditions. This is achieved by applying a fundamentally new physics-guided statistical approach involving: (i) ‘Self calibration’ where we calculate temperature from differential measurement of the ISEs induced by R2R variability to calibrate the sensors in uncontrolled temperature condition, and (ii) ‘Quorum sensing’ where we use a collection of R2R manufactured sensors to estimate the true concentration considering credibility of each sensor calculated by Bayesian Maximum Likelihood Estimation method. With these two new techniques, we demonstrate the use of “low-precision” R2R sensors to measure nitrate concentration of an agricultural field continuously over a period of 15 days within 10% of the ground-truth measured by the traditional high-precision commercial nitrate sensor.
{"title":"Embrace the Imperfection: How Intrinsic Variability of Roll-to-Roll Manufactured Environmental Sensors Enable Self-Calibrating, High-Precision Quorum Sensing","authors":"Ajanta Saha, Sarath Gopalakrishnan, J. Waimin, S. Sedaghat, Ye Mi, N. Glassmaker, Mukkerem Cakmak, A. Shakouri, R. Rahimi, Muhammad A. Alam","doi":"10.1115/msec2022-84878","DOIUrl":"https://doi.org/10.1115/msec2022-84878","url":null,"abstract":"\u0000 Roll-to-Roll (R2R) process is well suited for manufacturing low cost, miniaturized, solid contact Ion-selective electrodes (ISEs) of potentiometric sensors to be used for continuous monitoring of various analytes in environmental, industrial, and health-care applications. It is presumed that the intrinsic thickness variability of the R2R process would limit the accuracy of the ISE-based sensors and would make them inferior to sensors fabricated by higher precision manufacturing processes. Instead, in this paper we propose to use the intrinsic variability of R2R process as a “resource” to achieve high-accuracy sensing even when the sensors are operated in uncontrolled field conditions. This is achieved by applying a fundamentally new physics-guided statistical approach involving: (i) ‘Self calibration’ where we calculate temperature from differential measurement of the ISEs induced by R2R variability to calibrate the sensors in uncontrolled temperature condition, and (ii) ‘Quorum sensing’ where we use a collection of R2R manufactured sensors to estimate the true concentration considering credibility of each sensor calculated by Bayesian Maximum Likelihood Estimation method. With these two new techniques, we demonstrate the use of “low-precision” R2R sensors to measure nitrate concentration of an agricultural field continuously over a period of 15 days within 10% of the ground-truth measured by the traditional high-precision commercial nitrate sensor.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"215 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"90024599","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In the Industry 4.0 era, many emerging technologies are being embraced by manufacturers, including Digital Twin (DT) technology. DT has been known as a critical enabler for smart manufacturing and has attracted much attention from academia and industry. Meanwhile, the demand for DT platforms is growing as they enable more effective and easy development and deployment for DTs. DT expands to different industrial scenarios, which has led to an increasing variety of DT platforms. However, there are many different understandings and concepts of DT from diverse backgrounds, so it is essential to acquire a good understanding of DT platforms. This paper aims to provide a literature review of DT platforms in manufacturing. Firstly, the current state of DT technology is presented, and a generalized definition of the DT platform is proposed. A comprehensive search for literature related to the DT platform was conducted using the Web of Science database through the definition. Meanwhile, the importance of ISO 23247, an international standard on DT frameworks for manufacturing, has been discussed to give a general view of requirements for building a DT platform. After that, typical DT platforms in both academia and industry were analyzed separately. Finally, a discussion is carried out to summarise the architecture, features, and functions that are important for DT platform development.
在工业4.0时代，许多新兴技术正在被制造商所接受，其中包括数字孪生(DT)技术。数据挖掘作为智能制造的关键推动者，已经引起了学术界和工业界的广泛关注。与此同时，对DT平台的需求正在增长，因为它们能够更有效、更容易地开发和部署DT。DT扩展到不同的工业场景，导致DT平台的种类越来越多。然而，不同背景的人对DT有许多不同的理解和概念，因此有必要对DT平台有一个很好的了解。本文旨在对制造业中的DT平台进行文献综述。首先，介绍了DT技术的现状，提出了DT平台的广义定义。通过定义，利用Web of Science数据库对DT平台相关文献进行全面检索。与此同时，讨论了ISO 23247的重要性，这是一个关于制造业DT框架的国际标准，它给出了构建DT平台的总体要求。然后，分别对学术界和工业界的典型DT平台进行了分析。最后，对DT平台开发的重要架构、特性和功能进行了总结。
{"title":"Digital Twin Platforms: Architectures and Functions","authors":"Huiyue Huang, Tang Ji, Xun Xu","doi":"10.1115/msec2022-85085","DOIUrl":"https://doi.org/10.1115/msec2022-85085","url":null,"abstract":"\u0000 In the Industry 4.0 era, many emerging technologies are being embraced by manufacturers, including Digital Twin (DT) technology. DT has been known as a critical enabler for smart manufacturing and has attracted much attention from academia and industry. Meanwhile, the demand for DT platforms is growing as they enable more effective and easy development and deployment for DTs. DT expands to different industrial scenarios, which has led to an increasing variety of DT platforms. However, there are many different understandings and concepts of DT from diverse backgrounds, so it is essential to acquire a good understanding of DT platforms. This paper aims to provide a literature review of DT platforms in manufacturing. Firstly, the current state of DT technology is presented, and a generalized definition of the DT platform is proposed. A comprehensive search for literature related to the DT platform was conducted using the Web of Science database through the definition. Meanwhile, the importance of ISO 23247, an international standard on DT frameworks for manufacturing, has been discussed to give a general view of requirements for building a DT platform. After that, typical DT platforms in both academia and industry were analyzed separately. Finally, a discussion is carried out to summarise the architecture, features, and functions that are important for DT platform development.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"57 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"74634344","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Cyber physical system (CPS) of production line is an important technical support to realize the intelligent transformation of manufacturing industry. Therefore, this paper analyzes the application of CPS in the production line, and analyzes its modeling method in the production line; on this basis, the production line state signal analysis technology based on signal processing and deep learning algorithm is studied, which improves the quality of production line state monitoring. Based on the above analysis, this paper constructs the condition monitoring system framework of automobile parts production line based on CPS hybrid modeling, which overcomes the shortcomings of the traditional monitoring system and improves the analysis and decision-making ability of the system; In order to test the effectiveness of the framework, taking the spindle and bearing data in the automobile parts intelligent production line as an example, this paper compares the relevant algorithms, constructs a monitoring system based on the CPS framework, tests the effectiveness of the CPS framework in the condition monitoring of the intelligent production line, and proves that the framework can be popularized in the intelligent production line.
{"title":"Research on Condition Monitoring Technology of Automobile Parts Intelligent Production Line Based on Cyber Physical System","authors":"Yifei Wang, Zhiwen Xia, Kexin Yang, Lijun Jin","doi":"10.1115/msec2022-87425","DOIUrl":"https://doi.org/10.1115/msec2022-87425","url":null,"abstract":"\u0000 Cyber physical system (CPS) of production line is an important technical support to realize the intelligent transformation of manufacturing industry. Therefore, this paper analyzes the application of CPS in the production line, and analyzes its modeling method in the production line; on this basis, the production line state signal analysis technology based on signal processing and deep learning algorithm is studied, which improves the quality of production line state monitoring. Based on the above analysis, this paper constructs the condition monitoring system framework of automobile parts production line based on CPS hybrid modeling, which overcomes the shortcomings of the traditional monitoring system and improves the analysis and decision-making ability of the system; In order to test the effectiveness of the framework, taking the spindle and bearing data in the automobile parts intelligent production line as an example, this paper compares the relevant algorithms, constructs a monitoring system based on the CPS framework, tests the effectiveness of the CPS framework in the condition monitoring of the intelligent production line, and proves that the framework can be popularized in the intelligent production line.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"37 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"74645105","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Machining plays an important role in the prototyping process, and the carbide tools are often used in cutting tough metals under higher cutting speeds. Given the high degree of freedom and uncertainty in prototyping, conventional machine tools are generally favored by the machinists, and its low rigidity is more likely to cause chipping or breakage of the cutting edge in using carbide tools. However, due to the rapid development of chipping and the ever-changing toolpath in prototyping, the understanding of this type of tool damage is very limited from previous studies. To address this issue, the objective of this study is to experimentally investigate the chipping initiation and progression on the carbide tool under the prototyping circumstances. The experimental results indicate that the chipping develops differently at different locations on the cutting edge and under different cutting conditions and propagates rapidly when the maximum width of the local chipping reaches the critical value. It was also found that the chipping propagation is influenced by the interactions between the chipping and the flank wear and chipping among different flutes. To consider all those factors into chipping characterization and monitoring in milling, a combined failure criterion has been proposed in this study.
{"title":"An Investigation of Chipping Propagation on Carbide Tool in End Milling for Prototyping","authors":"Shuhuan Zhang, R. Liu","doi":"10.1115/msec2022-85822","DOIUrl":"https://doi.org/10.1115/msec2022-85822","url":null,"abstract":"\u0000 Machining plays an important role in the prototyping process, and the carbide tools are often used in cutting tough metals under higher cutting speeds. Given the high degree of freedom and uncertainty in prototyping, conventional machine tools are generally favored by the machinists, and its low rigidity is more likely to cause chipping or breakage of the cutting edge in using carbide tools. However, due to the rapid development of chipping and the ever-changing toolpath in prototyping, the understanding of this type of tool damage is very limited from previous studies. To address this issue, the objective of this study is to experimentally investigate the chipping initiation and progression on the carbide tool under the prototyping circumstances. The experimental results indicate that the chipping develops differently at different locations on the cutting edge and under different cutting conditions and propagates rapidly when the maximum width of the local chipping reaches the critical value. It was also found that the chipping propagation is influenced by the interactions between the chipping and the flank wear and chipping among different flutes. To consider all those factors into chipping characterization and monitoring in milling, a combined failure criterion has been proposed in this study.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"16 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"85659788","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Laser powder bed fusion (L-PBF) additive manufacturing has been used to fabricate complex-shaped structures, which often consist of fine features. Due to transient process phenomena, there are differences in terms of the melt pool formation and the surface morphology depending upon the feature area and scan parameters. This study investigates the scan length effect on the surface morphology and the presence of transient length and width that may have a significant effect as the layer addition continues. For this purpose, four scan lengths (0.25 mm, 0.5 mm, 1.0 mm, and 2.0 mm) are used to fabricate six tracks with back-and-forth scanning. A full factorial design of experiments is used to form multi-track depositions with three levels of power (125 W, 160 W, and 195 W), two levels of scan speed (550 mm/s and 1000 mm/s), and four levels of hatch spacing (80 μm, 100 μm, 120 μm, and 140 μm). A white light interferometer is used to acquire the surface data, and MATLAB is used for surface topographical analysis. The results indicated that the scan length has a significant effect on the surface characteristics. The average height of multi-track deposits increases with the decrease of the scan length. Moreover, the transient length and width can be approximated based on the height variation along both the scan and transverse directions, respectively.
激光粉末床熔融(L-PBF)增材制造已被用于制造复杂形状的结构，这些结构通常由精细的特征组成。由于瞬态过程现象的存在，不同的特征区域和扫描参数在熔池形成和表面形貌方面存在差异。本研究研究了扫描长度对表面形貌的影响，以及随着层的增加，可能产生显著影响的瞬态长度和宽度的存在。为此，使用四种扫描长度(0.25 mm, 0.5 mm, 1.0 mm和2.0 mm)来制造六个轨道，并进行来回扫描。采用全因子实验设计，在三种功率(125 W、160 W和195 W)、两种扫描速度(550 mm/s和1000 mm/s)和四种舱口间距(80 μm、100 μm、120 μm和140 μm)下形成多道沉积。利用白光干涉仪采集表面数据，利用MATLAB进行表面形貌分析。结果表明，扫描长度对表面特性有显著影响。随着扫描长度的减小，多道沉积体的平均高度增大。此外，瞬态长度和宽度可以分别根据扫描方向和横向高度的变化来近似计算。
{"title":"An Investigation Into Multi-Track Deposition in Laser Powder-Bed Fusion: Transient Regions Analysis and Scan Length Effects","authors":"S. Rauniyar, Subin Shrestha, K. Chou","doi":"10.1115/msec2022-85746","DOIUrl":"https://doi.org/10.1115/msec2022-85746","url":null,"abstract":"\u0000 Laser powder bed fusion (L-PBF) additive manufacturing has been used to fabricate complex-shaped structures, which often consist of fine features. Due to transient process phenomena, there are differences in terms of the melt pool formation and the surface morphology depending upon the feature area and scan parameters. This study investigates the scan length effect on the surface morphology and the presence of transient length and width that may have a significant effect as the layer addition continues. For this purpose, four scan lengths (0.25 mm, 0.5 mm, 1.0 mm, and 2.0 mm) are used to fabricate six tracks with back-and-forth scanning. A full factorial design of experiments is used to form multi-track depositions with three levels of power (125 W, 160 W, and 195 W), two levels of scan speed (550 mm/s and 1000 mm/s), and four levels of hatch spacing (80 μm, 100 μm, 120 μm, and 140 μm). A white light interferometer is used to acquire the surface data, and MATLAB is used for surface topographical analysis. The results indicated that the scan length has a significant effect on the surface characteristics. The average height of multi-track deposits increases with the decrease of the scan length. Moreover, the transient length and width can be approximated based on the height variation along both the scan and transverse directions, respectively.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"199 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86493197","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
One of the challenges to multimaterial multifunctional composite fibers is their scalability during the fabrication process. Additive manufacturing is a cost-effective tooling solution for fast prototyping fiber spinning spinnerets. This work demonstrates a laser powder bed fusion-based tri-axial spinneret that could accommodate three different materials as inner, middle, and outer layers. In the first work, continuous graphene nanoplatelets (GnPs) channel was embedded between core polymer and sheath polymer layers to simultaneously achieve electrical conductivity and high mechanical properties. This multimateiral, multichannel system is too expensive with conventional manufacturing. Our 3D printed spinneret will generate shear stress during the polymer drawing process, resulting in thinning and alignment of the two-dimensional (2D) GnPs. Similarly, in the second research, a multilayered chemiresistor for volatile organic compounds (VOCs) was fabricated in a single step. Each layer played a significant role in the overall sensor functionalities. For instance, (i) the hollow core supported inline gas transportation, (ii) the porous polymer inner layer assisted VOC diffusion, (iii) the middle electrical conductive layer responded to VOCs types and concentrations, and (iv) the outer mechanically stable layer secured sensor’s physical stability.
{"title":"Tooling Engineering and its Role in Manipulating Fiber Spinning and Enabled Nanostructures","authors":"Weiheng Xu, Kenan Song","doi":"10.1115/msec2022-85065","DOIUrl":"https://doi.org/10.1115/msec2022-85065","url":null,"abstract":"\u0000 One of the challenges to multimaterial multifunctional composite fibers is their scalability during the fabrication process. Additive manufacturing is a cost-effective tooling solution for fast prototyping fiber spinning spinnerets. This work demonstrates a laser powder bed fusion-based tri-axial spinneret that could accommodate three different materials as inner, middle, and outer layers. In the first work, continuous graphene nanoplatelets (GnPs) channel was embedded between core polymer and sheath polymer layers to simultaneously achieve electrical conductivity and high mechanical properties. This multimateiral, multichannel system is too expensive with conventional manufacturing. Our 3D printed spinneret will generate shear stress during the polymer drawing process, resulting in thinning and alignment of the two-dimensional (2D) GnPs. Similarly, in the second research, a multilayered chemiresistor for volatile organic compounds (VOCs) was fabricated in a single step. Each layer played a significant role in the overall sensor functionalities. For instance, (i) the hollow core supported inline gas transportation, (ii) the porous polymer inner layer assisted VOC diffusion, (iii) the middle electrical conductive layer responded to VOCs types and concentrations, and (iv) the outer mechanically stable layer secured sensor’s physical stability.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"97 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"88116254","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Aerospace composites assemblies/joining demand ultra-high precision due to critical safety requirements, which necessitate adherence to indicators of risk that are often difficult to quantify. This study examines one important indicator, the residual stress that arises as a result of dimensional mismatch between mating components during the composite structures assembly process. Conventional simulations of large components assemblies investigated the process at a local or global scale, but lacked detailed exploitation of multi-layer stress analysis at integrated scale for composite structures. We develop a novel digital twin simulation for joining large composite structures with mechanical fasteners. The digital twin simulation integrates global features and local features for detailed investigation of stresses. We perform a statistical analysis to better understand the numerical properties of residual stresses after the fastening. Goodness-of-Fit tests and normality tests are used to explore the probabilistic distributions of the stresses exceeding a chosen safety threshold. The case study is conducted based on composite fuselage joining. The results show the stresses in composite structures assembly follow extreme value distributions (such as Weibull, Gumbel) rather than the widely used Gaussian distribution. The stresses in joined composite structures differ across layers, which can be attributed to the anisotropic material behavior.
{"title":"Towards a Digital Twin: Simulation and Residual Stress Analysis in Aerospace Composite Structures Assembly","authors":"Tim Lutz, X. Yue, J. Camelio","doi":"10.1115/msec2022-85439","DOIUrl":"https://doi.org/10.1115/msec2022-85439","url":null,"abstract":"\u0000 Aerospace composites assemblies/joining demand ultra-high precision due to critical safety requirements, which necessitate adherence to indicators of risk that are often difficult to quantify. This study examines one important indicator, the residual stress that arises as a result of dimensional mismatch between mating components during the composite structures assembly process. Conventional simulations of large components assemblies investigated the process at a local or global scale, but lacked detailed exploitation of multi-layer stress analysis at integrated scale for composite structures. We develop a novel digital twin simulation for joining large composite structures with mechanical fasteners. The digital twin simulation integrates global features and local features for detailed investigation of stresses. We perform a statistical analysis to better understand the numerical properties of residual stresses after the fastening. Goodness-of-Fit tests and normality tests are used to explore the probabilistic distributions of the stresses exceeding a chosen safety threshold. The case study is conducted based on composite fuselage joining. The results show the stresses in composite structures assembly follow extreme value distributions (such as Weibull, Gumbel) rather than the widely used Gaussian distribution. The stresses in joined composite structures differ across layers, which can be attributed to the anisotropic material behavior.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"103 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"78748000","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Chaitanya Krishna Prasad Vallabh, Shawn Hinnebusch, A. To, Xiayun Zhao
In metal additive manufacturing (AM) the layer-wise thermal history is crucial for its effect on the print part properties, such as, microstructure, porosity, and mechanical strength. Literature studies for evaluating the part thermal history are typically based on in-situ infrared thermography and thermal modeling. However, the effect of melt pool temperature on the part thermal history has not been widely studied. In this preliminary work, for the first time we present a large and comprehensive in-situ monitored, layer-wise melt pool temperature evolution data for laser powder bed fusion (LPBF) AM. The melt pool temperature is evaluated using an in-house Single Camera Two-Wavelength Imaging Pyrometry (STWIP) system. The melt pool temperature evolution was evaluated for three different prints with different inter-layer-times and print heights. The melt pool temperature history trends presented in this work are in agreement with literature studies on part-thermal histories. The LPBF process signatures from our STWIP system can help develop more accurate thermal models with the melt pool temperature as the input and the unique capability of the STWIP system to acquire and analyze large amounts data facilitates the development of machine learning models for estimating part properties based on the process signatures.
{"title":"Layer-Wise Melt Pool Temperature Evolution in Laser Powder Bed Fusion: An Experimental Study Using a Single Camera Based Two-Wavelength Imaging Pyrometry","authors":"Chaitanya Krishna Prasad Vallabh, Shawn Hinnebusch, A. To, Xiayun Zhao","doi":"10.1115/msec2022-85387","DOIUrl":"https://doi.org/10.1115/msec2022-85387","url":null,"abstract":"\u0000 In metal additive manufacturing (AM) the layer-wise thermal history is crucial for its effect on the print part properties, such as, microstructure, porosity, and mechanical strength. Literature studies for evaluating the part thermal history are typically based on in-situ infrared thermography and thermal modeling. However, the effect of melt pool temperature on the part thermal history has not been widely studied. In this preliminary work, for the first time we present a large and comprehensive in-situ monitored, layer-wise melt pool temperature evolution data for laser powder bed fusion (LPBF) AM. The melt pool temperature is evaluated using an in-house Single Camera Two-Wavelength Imaging Pyrometry (STWIP) system. The melt pool temperature evolution was evaluated for three different prints with different inter-layer-times and print heights. The melt pool temperature history trends presented in this work are in agreement with literature studies on part-thermal histories. The LPBF process signatures from our STWIP system can help develop more accurate thermal models with the melt pool temperature as the input and the unique capability of the STWIP system to acquire and analyze large amounts data facilitates the development of machine learning models for estimating part properties based on the process signatures.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"13 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"83657399","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Rebecca Kurfess, R. Kannan, T. Feldhausen, K. Saleeby, A. Hart, D. Hardt
Directed energy deposition (DED) is increasingly considered for manufacturing aerospace components and mold tooling with internal cooling channels, and for repair applications, but the design space of DED is limited: steep overhangs and bridge geometries are difficult or impossible to manufacture because support structures must be rigid and monolithic. Dissimilar metals may be used as supports, but these have proven difficult to manufacture and remove. Polymer supports in DED could provide a lower-cost, easily removable alternative, but the suitability of polymer substrates for DED components has not been explored. Crucial to the viability of this concept is understanding the thermal and mechanical stability of metal deposition onto polymers, and the properties of the solidified metal. Here, the deposition of 316L stainless steel onto carbon-fiber-reinforced ABS is investigated. Solid, box-shaped structures were manufactured with different inter-layer cooling times to study the interface between the metal and polymer composite and to determine the effect on the metal of the formation of carbonaceous polymer char generated during the DED process. Micro-hardness measurements across components with varying inter-layer cooling times were critically analyzed and correlated to the underlying structural changes in 316L at the interface. Due to the infiltration of char, the hardness of the metal directly adjacent to the polymer composite substrate was over 60% greater than the expected hardness value of deposited 316L stainless steel in the component with no interlayer cooling time.
{"title":"Towards Directed Energy Deposition of Metals Using Polymer-Based Supports: Hardness of 316L Stainless Steel Deposited on Carbon-Fiber-Reinforced ABS","authors":"Rebecca Kurfess, R. Kannan, T. Feldhausen, K. Saleeby, A. Hart, D. Hardt","doi":"10.1115/msec2022-85562","DOIUrl":"https://doi.org/10.1115/msec2022-85562","url":null,"abstract":"\u0000 Directed energy deposition (DED) is increasingly considered for manufacturing aerospace components and mold tooling with internal cooling channels, and for repair applications, but the design space of DED is limited: steep overhangs and bridge geometries are difficult or impossible to manufacture because support structures must be rigid and monolithic. Dissimilar metals may be used as supports, but these have proven difficult to manufacture and remove. Polymer supports in DED could provide a lower-cost, easily removable alternative, but the suitability of polymer substrates for DED components has not been explored. Crucial to the viability of this concept is understanding the thermal and mechanical stability of metal deposition onto polymers, and the properties of the solidified metal. Here, the deposition of 316L stainless steel onto carbon-fiber-reinforced ABS is investigated. Solid, box-shaped structures were manufactured with different inter-layer cooling times to study the interface between the metal and polymer composite and to determine the effect on the metal of the formation of carbonaceous polymer char generated during the DED process. Micro-hardness measurements across components with varying inter-layer cooling times were critically analyzed and correlated to the underlying structural changes in 316L at the interface. Due to the infiltration of char, the hardness of the metal directly adjacent to the polymer composite substrate was over 60% greater than the expected hardness value of deposited 316L stainless steel in the component with no interlayer cooling time.","PeriodicalId":23676,"journal":{"name":"Volume 2: Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability","volume":"26 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"75237469","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：