Dimensional accuracies are affected due to various factors which include warping, ambient temperature, material properties, etc. In-situ process monitoring and controlling in additive manufacturing is one of the ways to reduce defects in three-dimensional (3D) printed parts through continuous monitoring and correcting the process parameters. By considering the dimensions of a printed part, the part is usually inspected after completing the printing process. In this study, a new method for determining dimensional values of fused deposition modeling printed parts during the printing process is proposed using the Open-source Computer Vision Library (OpenCV). This method of determining the dimensions of a part would be useful for a user to verify the dimensions of the part being built at various stages. This could ensure the dimensional accuracy of the part is constant throughout the printing. By adopting this method to measure the dimensions, prevents wastage of material with poor dimensional accuracy and saves time by producing only accurate parts.
{"title":"Measurement of additively manufactured part dimensions using OpenCV for process monitoring","authors":"Pradeep Castro, Gurusamy Pathinettampadian, Sarankumar Thanigainathan, Vignesh Prabakar, Rahul Anandha Krishnan, M. Subramaniyan","doi":"10.1177/09544089241227894","DOIUrl":"https://doi.org/10.1177/09544089241227894","url":null,"abstract":"Dimensional accuracies are affected due to various factors which include warping, ambient temperature, material properties, etc. In-situ process monitoring and controlling in additive manufacturing is one of the ways to reduce defects in three-dimensional (3D) printed parts through continuous monitoring and correcting the process parameters. By considering the dimensions of a printed part, the part is usually inspected after completing the printing process. In this study, a new method for determining dimensional values of fused deposition modeling printed parts during the printing process is proposed using the Open-source Computer Vision Library (OpenCV). This method of determining the dimensions of a part would be useful for a user to verify the dimensions of the part being built at various stages. This could ensure the dimensional accuracy of the part is constant throughout the printing. By adopting this method to measure the dimensions, prevents wastage of material with poor dimensional accuracy and saves time by producing only accurate parts.","PeriodicalId":506108,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"212 ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140485495","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}
Pub Date : 2024-01-30DOI: 10.1177/09544089231218104
Guang-hui Yang, Xin Ji
In this article, six ceramic-filled glass fiber (GF)/PTFE-based composites were fabricated using 15 wt.% mass fraction GF and 80 wt.% PTFE as matrix materials and 5 wt.% mass fraction ceramic materials such as Al2O3, MoS2, TiO2, BaSO4, hollow glass beads (HGB), and solid glass beads (SGB) as filler materials, respectively, at 44 MPa molding pressure and sintering temperature of 370°C. The tensile strength, elongation at break, and compressive strength at room temperature and 250°C were investigated for six composites. Finally, the surface morphology of the composites was characterized using the ultradeep field electron microscope. The results show that MoS2 has the best synergistic strengthening effect with GF in PTFE matrix, but the toughening effect is less obvious, so MoS2/GF/PTFE exhibits the maximum hardness (66) and tensile strength (18.16 MPa) and the minimum elongation at break (94.72%), while HGB/GF/PTFE composites exhibit the minimum hardness (61) and tensile strength (15.04 MPa) and the maximum elongation at break (360.36%). In addition, the MoS2/GF/PTFE exhibited the maximum compressive strength (9.29 MPa) at 250°C, but then the SGB/GF/PTFE composite exhibited the maximum compressive strength (24.28) at room temperature. A comprehensive analysis of the modification mechanism shows that the type, morphology, particle size, strength, and interfacial bonding with the PTFE matrix of the ceramic filler all influence the filling effect of the composite.
{"title":"Effect of different ceramic fillers filled with GF/PTFE on the tensile and compressive properties of the composites","authors":"Guang-hui Yang, Xin Ji","doi":"10.1177/09544089231218104","DOIUrl":"https://doi.org/10.1177/09544089231218104","url":null,"abstract":"In this article, six ceramic-filled glass fiber (GF)/PTFE-based composites were fabricated using 15 wt.% mass fraction GF and 80 wt.% PTFE as matrix materials and 5 wt.% mass fraction ceramic materials such as Al2O3, MoS2, TiO2, BaSO4, hollow glass beads (HGB), and solid glass beads (SGB) as filler materials, respectively, at 44 MPa molding pressure and sintering temperature of 370°C. The tensile strength, elongation at break, and compressive strength at room temperature and 250°C were investigated for six composites. Finally, the surface morphology of the composites was characterized using the ultradeep field electron microscope. The results show that MoS2 has the best synergistic strengthening effect with GF in PTFE matrix, but the toughening effect is less obvious, so MoS2/GF/PTFE exhibits the maximum hardness (66) and tensile strength (18.16 MPa) and the minimum elongation at break (94.72%), while HGB/GF/PTFE composites exhibit the minimum hardness (61) and tensile strength (15.04 MPa) and the maximum elongation at break (360.36%). In addition, the MoS2/GF/PTFE exhibited the maximum compressive strength (9.29 MPa) at 250°C, but then the SGB/GF/PTFE composite exhibited the maximum compressive strength (24.28) at room temperature. A comprehensive analysis of the modification mechanism shows that the type, morphology, particle size, strength, and interfacial bonding with the PTFE matrix of the ceramic filler all influence the filling effect of the composite.","PeriodicalId":506108,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"65 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140481709","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}
Pub Date : 2024-01-17DOI: 10.1177/09544089231221529
Saowalak Kongiang, Siriporn Rojananan, S. Thipprakmas
Die cutting is a well-known process of sheet metal forming for separating sheet metal into the required shape. Compared with other cutting processes such as machining, this process has the advantages of a high production rate and low production cost. Currently, as a necessary process in sheet metal manufacturing, this process has been researched to improve the efficiency of the process and quality of cut components. In this study, the application of cryogenics in the die-cutting process was investigated, and the characteristics of the cut surfaces were examined. The shearing process was investigated using a die-cutting model. An aluminum alloy grade A5083 (JIS standard) was used as the workpiece. After shearing, the physical characteristics of the cut surfaces were examined using a 3-D laser scanner. Shear forces were also reported. The grain evolution in the shearing zone was also investigated. The results revealed that compared with the shearing process at room temperature, the ratio of clean cut to workpiece thickness was slightly increased. However, they showed differences in fracture characteristics. A concave feature in the fracture zone was generated at the cryogenic temperature, particularly for small clearances. These results were clearly explained based on the initial fracture angle and its propagation, and grain evolution. Based on the changes in the material properties at cryogenic temperatures, an elongated grain structure was easily generated, resulting in a larger initial fracture compared with that of the shearing process at room temperature. This is important when using the cut component, as the strength of the cut part decreases owing to the larger concave features. In addition, it provides helpful information on cut components that may require additional operations.
{"title":"Cut surface characteristics of aluminum alloy sheet in cryogenic shearing process","authors":"Saowalak Kongiang, Siriporn Rojananan, S. Thipprakmas","doi":"10.1177/09544089231221529","DOIUrl":"https://doi.org/10.1177/09544089231221529","url":null,"abstract":"Die cutting is a well-known process of sheet metal forming for separating sheet metal into the required shape. Compared with other cutting processes such as machining, this process has the advantages of a high production rate and low production cost. Currently, as a necessary process in sheet metal manufacturing, this process has been researched to improve the efficiency of the process and quality of cut components. In this study, the application of cryogenics in the die-cutting process was investigated, and the characteristics of the cut surfaces were examined. The shearing process was investigated using a die-cutting model. An aluminum alloy grade A5083 (JIS standard) was used as the workpiece. After shearing, the physical characteristics of the cut surfaces were examined using a 3-D laser scanner. Shear forces were also reported. The grain evolution in the shearing zone was also investigated. The results revealed that compared with the shearing process at room temperature, the ratio of clean cut to workpiece thickness was slightly increased. However, they showed differences in fracture characteristics. A concave feature in the fracture zone was generated at the cryogenic temperature, particularly for small clearances. These results were clearly explained based on the initial fracture angle and its propagation, and grain evolution. Based on the changes in the material properties at cryogenic temperatures, an elongated grain structure was easily generated, resulting in a larger initial fracture compared with that of the shearing process at room temperature. This is important when using the cut component, as the strength of the cut part decreases owing to the larger concave features. In addition, it provides helpful information on cut components that may require additional operations.","PeriodicalId":506108,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"55 25","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139527830","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}
Pub Date : 2024-01-10DOI: 10.1177/09544089231224324
Kutay Celebioglu, Ece Aylı, Huseyin Cetinturk, Y. Taşcıoğlu, S. Aradag
In this study, investigations were conducted using computational fluid dynamics (CFD) to assess the applicability of a Francis-type water turbine within a pipe. The objective of the study is to determine the feasibility of implementing a turbine within a pipe and enhance its performance values within the operating range. The turbine within the pipe occupies significantly less space in hydroelectric power plants since a spiral casing is not used to distribute the flow to stationary vanes. Consequently, production and assembly costs can be reduced. Hence, there is a broad scope for application, particularly in small and medium-scale hydroelectric power plants. According to the results, the efficiency value increases on average by approximately 1.5% compared to conventional design, and it operates with higher efficiencies over a wider flow rate range. In the second part of the study, machine learning was employed for the efficiency prediction of an inline-type turbine. An appropriate Artificial Neural Network (ANN) architecture was initially obtained, with the Bayesian Regularization training algorithm proving to be the best approach for this type of problem. When the suitable ANN architecture was utilized, the prediction was found to be in good agreement with CFD, with an root mean squared error value of 0.194. An R2 value of 0.99631 was achieved with the appropriate ANN architecture.
本研究使用计算流体动力学（CFD）进行了调查，以评估管道内混流式水轮机的适用性。研究的目的是确定在管道内安装水轮机的可行性，并提高其在运行范围内的性能值。由于无需使用蜗壳将水流分配到固定叶片上，管内水轮机占用的水电站空间大大减少。因此，可以降低生产和装配成本。因此，应用范围非常广泛，尤其是在中小型水电站中。研究结果表明，与传统设计相比，效率值平均提高了约 1.5%，而且在更宽的流量范围内都能以更高的效率运行。研究的第二部分采用了机器学习方法来预测直列式水轮机的效率。最初，我们获得了一个合适的人工神经网络（ANN）架构，贝叶斯正则化训练算法被证明是解决此类问题的最佳方法。使用合适的人工神经网络架构后，发现预测结果与 CFD 非常吻合，均方根误差值为 0.194。采用适当的 ANN 结构后，R2 值达到 0.99631。
{"title":"Exploring the potential of artificial intelligence tools in enhancing the performance of an inline pipe turbine","authors":"Kutay Celebioglu, Ece Aylı, Huseyin Cetinturk, Y. Taşcıoğlu, S. Aradag","doi":"10.1177/09544089231224324","DOIUrl":"https://doi.org/10.1177/09544089231224324","url":null,"abstract":"In this study, investigations were conducted using computational fluid dynamics (CFD) to assess the applicability of a Francis-type water turbine within a pipe. The objective of the study is to determine the feasibility of implementing a turbine within a pipe and enhance its performance values within the operating range. The turbine within the pipe occupies significantly less space in hydroelectric power plants since a spiral casing is not used to distribute the flow to stationary vanes. Consequently, production and assembly costs can be reduced. Hence, there is a broad scope for application, particularly in small and medium-scale hydroelectric power plants. According to the results, the efficiency value increases on average by approximately 1.5% compared to conventional design, and it operates with higher efficiencies over a wider flow rate range. In the second part of the study, machine learning was employed for the efficiency prediction of an inline-type turbine. An appropriate Artificial Neural Network (ANN) architecture was initially obtained, with the Bayesian Regularization training algorithm proving to be the best approach for this type of problem. When the suitable ANN architecture was utilized, the prediction was found to be in good agreement with CFD, with an root mean squared error value of 0.194. An R2 value of 0.99631 was achieved with the appropriate ANN architecture.","PeriodicalId":506108,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"66 20","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139534862","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}
Pub Date : 2024-01-10DOI: 10.1177/09544089231225147
A. Riyaz Ahmed, V. Mugendiran
A widely existent method of fabricating 3D printed parts by polylactic acid (PLA) is by fused deposition modeling, which faces a poor surface finish when compared to resin-based 3D printing methods. The focus of the current work is to leverage LCD 3D printing to produce 3D printed PLA parts with improved strength and surface quality. Tensile, impact, and flexural specimens with varying layer thicknesses were printed and postcured to explore the mechanical properties. It was found that by increasing the layer thickness and minimizing the postcuring time, printed samples with maximum strength can be obtained. Further, rheological characterization was done to test whether the same resin is suitable for usage as raw material in direct ink write 3D printing and it was found that the resin with 4 wt. % and 5wt. % fumed silica were suitable for direct ink writing.
{"title":"Effect of process parameters on mechanical properties of PLA resin through LCD 3D printing","authors":"A. Riyaz Ahmed, V. Mugendiran","doi":"10.1177/09544089231225147","DOIUrl":"https://doi.org/10.1177/09544089231225147","url":null,"abstract":"A widely existent method of fabricating 3D printed parts by polylactic acid (PLA) is by fused deposition modeling, which faces a poor surface finish when compared to resin-based 3D printing methods. The focus of the current work is to leverage LCD 3D printing to produce 3D printed PLA parts with improved strength and surface quality. Tensile, impact, and flexural specimens with varying layer thicknesses were printed and postcured to explore the mechanical properties. It was found that by increasing the layer thickness and minimizing the postcuring time, printed samples with maximum strength can be obtained. Further, rheological characterization was done to test whether the same resin is suitable for usage as raw material in direct ink write 3D printing and it was found that the resin with 4 wt. % and 5wt. % fumed silica were suitable for direct ink writing.","PeriodicalId":506108,"journal":{"name":"Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering","volume":"56 17","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139534880","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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