Pub Date : 2024-03-26DOI: 10.1108/rpj-08-2023-0287
S. de la Rosa, P. Mayuet, Cátia S. Silva, Álvaro M. Sampaio, L. Rodríguez-Parada
Purpose This papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour for their application in a methodology for the design and development of personalized elastic therapeutic products. Design/methodology/approach Lattice samples were designed and manufactured using extrusion-based additive manufacturing technologies. Mechanical tests were carried out on lattice samples for elasticity characterization purposes. The relationships between sample stiffness and key geometric and manufacturing variables were subsequently used in the case study on the design of a pressure cushion model for validation purposes. Differentiated areas were established according to patient’s pressure map to subsequently make a correlation between the patient’s pressure needs and lattice samples stiffness. Findings A substantial and wide variation in lattice compressive behaviour was found depending on the key study variables. The proposed methodology made it possible to efficiently identify and adjust the pressure of the different areas of the product to adapt them to the elastic needs of the patient. In this sense, the characterization lattice samples turned out to provide an effective and flexible response to the pressure requirements. Originality/value This study provides a generalized foundation of lattice structural design and adjustable stiffness in application of pressure cushions, which can be equally applied to other designs with similar purposes. The relevance and contribution of this work lie in the proposed methodology for the design of personalized therapeutic products based on the use of individual lattice structures that function as independent customizable cells.
{"title":"Design and characterization of 3D-printed TPU-based lattice structures. Application to methodology for the design of personalized therapeutic products","authors":"S. de la Rosa, P. Mayuet, Cátia S. Silva, Álvaro M. Sampaio, L. Rodríguez-Parada","doi":"10.1108/rpj-08-2023-0287","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0287","url":null,"abstract":"\u0000Purpose\u0000This papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour for their application in a methodology for the design and development of personalized elastic therapeutic products.\u0000\u0000\u0000Design/methodology/approach\u0000Lattice samples were designed and manufactured using extrusion-based additive manufacturing technologies. Mechanical tests were carried out on lattice samples for elasticity characterization purposes. The relationships between sample stiffness and key geometric and manufacturing variables were subsequently used in the case study on the design of a pressure cushion model for validation purposes. Differentiated areas were established according to patient’s pressure map to subsequently make a correlation between the patient’s pressure needs and lattice samples stiffness.\u0000\u0000\u0000Findings\u0000A substantial and wide variation in lattice compressive behaviour was found depending on the key study variables. The proposed methodology made it possible to efficiently identify and adjust the pressure of the different areas of the product to adapt them to the elastic needs of the patient. In this sense, the characterization lattice samples turned out to provide an effective and flexible response to the pressure requirements.\u0000\u0000\u0000Originality/value\u0000This study provides a generalized foundation of lattice structural design and adjustable stiffness in application of pressure cushions, which can be equally applied to other designs with similar purposes. The relevance and contribution of this work lie in the proposed methodology for the design of personalized therapeutic products based on the use of individual lattice structures that function as independent customizable cells.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"108 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140379614","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 : 2024-02-29DOI: 10.1108/rpj-06-2023-0202
Jie Wan, Biao Chen, Jianghua Shen, K. Kondoh, Shuiqing Liu, Jinshan Li
Purpose The metallic alloys and their components fabricated via laser powder bed fusion (LPBF) suffer from the microvoids formed inevitably due to the extreme solidification rate during fabrication, which are impossible to be removed by heat treatment. This paper aims to remove those microvoids in as-built AlSi10Mg alloys by hot forging and enhance their mechanical properties. Design/methodology/approach AlSi10Mg samples were built using prealloyed powder with a set of optimized LPBF parameters, viz. 350 W of laser power, 1,170 mm/s of scan speed, 50 µm of layer thickness and 0.24 mm of hatch spacing. As-built samples were preheated to 430°C followed by immediate pressing with two different thickness reductions of 10% and 35%. The effect of hot forging on the microstructure was analyzed by means of X-ray diffraction, scanning electron microscopy, electron backscattered diffraction and transmission electron microscopy. Tensile tests were performed to reveal the effect of hot forging on the mechanical properties. Findings By using hot forging, the large number of microvoids in both as-built and post heat-treated samples were mostly healed. Moreover, the Si particles were finer in forged condition (∼150 nm) compared with those in heat-treated condition (∼300 nm). Tensile tests showed that compared with heat treatment, the hot forging process could noticeably increase tensile strength at no expense of ductility. Consequently, the toughness (integration of tensile stress and strain) of forged alloy increased by ∼86% and ∼24% compared with as-built and heat-treated alloys, respectively. Originality/value Hot forging can effectively remove the inevitable microvoids in metals fabricated via LPBF, which is beneficial to the mechanical properties. These findings are inspiring for the evolution of the LPBF technique to eliminate the microvoids and boost the mechanical properties of metals fabricated via LPBF.
{"title":"Improving the mechanical properties of laser powder bed fused AlSi10Mg alloys by eliminating the inevitable micro-voids via hot forging","authors":"Jie Wan, Biao Chen, Jianghua Shen, K. Kondoh, Shuiqing Liu, Jinshan Li","doi":"10.1108/rpj-06-2023-0202","DOIUrl":"https://doi.org/10.1108/rpj-06-2023-0202","url":null,"abstract":"\u0000Purpose\u0000The metallic alloys and their components fabricated via laser powder bed fusion (LPBF) suffer from the microvoids formed inevitably due to the extreme solidification rate during fabrication, which are impossible to be removed by heat treatment. This paper aims to remove those microvoids in as-built AlSi10Mg alloys by hot forging and enhance their mechanical properties.\u0000\u0000\u0000Design/methodology/approach\u0000AlSi10Mg samples were built using prealloyed powder with a set of optimized LPBF parameters, viz. 350 W of laser power, 1,170 mm/s of scan speed, 50 µm of layer thickness and 0.24 mm of hatch spacing. As-built samples were preheated to 430°C followed by immediate pressing with two different thickness reductions of 10% and 35%. The effect of hot forging on the microstructure was analyzed by means of X-ray diffraction, scanning electron microscopy, electron backscattered diffraction and transmission electron microscopy. Tensile tests were performed to reveal the effect of hot forging on the mechanical properties.\u0000\u0000\u0000Findings\u0000By using hot forging, the large number of microvoids in both as-built and post heat-treated samples were mostly healed. Moreover, the Si particles were finer in forged condition (∼150 nm) compared with those in heat-treated condition (∼300 nm). Tensile tests showed that compared with heat treatment, the hot forging process could noticeably increase tensile strength at no expense of ductility. Consequently, the toughness (integration of tensile stress and strain) of forged alloy increased by ∼86% and ∼24% compared with as-built and heat-treated alloys, respectively.\u0000\u0000\u0000Originality/value\u0000Hot forging can effectively remove the inevitable microvoids in metals fabricated via LPBF, which is beneficial to the mechanical properties. These findings are inspiring for the evolution of the LPBF technique to eliminate the microvoids and boost the mechanical properties of metals fabricated via LPBF.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"82 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140411348","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 : 2024-02-28DOI: 10.1108/rpj-06-2023-0190
L. Mizzi, Arrigo Simonetti, Andrea Spaggiari
Purpose The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved geometric versatility over traditional chiral honeycombs. This paper aims to design and manufacture chiral honeycombs representative of four distinct classes of 2D Euclidean tessellations with hexagonal rotational symmetry using fused-deposition additive manufacturing and experimentally analysed the mechanical properties and failure modes of these metamaterials. Design/methodology/approach Finite Element simulations were also used to study the high-strain compressive performance of these systems under both periodic boundary conditions and realistic, finite conditions. Experimental uniaxial compressive loading tests were applied to additively manufactured prototypes and digital image correlation was used to measure the Poisson’s ratio and analyse the deformation behaviour of these systems. Findings The results obtained demonstrate that these systems have the ability to exhibit a wide range of Poisson’s ratios (positive, quasi-zero and negative values) and stiffnesses as well as unusual failure modes characterised by a sequential layer-by-layer collapse of specific, non-adjacent ligaments. These findings provide useful insights on the mechanical properties and deformation behaviours of this new class of metamaterials and indicate that these chiral honeycombs could potentially possess anomalous characteristics which are not commonly found in traditional chiral metamaterials based on regular monohedral tilings. Originality/value To the best of the authors’ knowledge, the authors have analysed for the first time the high strain behaviour and failure modes of chiral metamaterials based on Euclidean multi-polygonal tessellations.
{"title":"Mechanical properties and failure modes of additively-manufactured chiral metamaterials based on Euclidean tessellations: an experimental and finite element study","authors":"L. Mizzi, Arrigo Simonetti, Andrea Spaggiari","doi":"10.1108/rpj-06-2023-0190","DOIUrl":"https://doi.org/10.1108/rpj-06-2023-0190","url":null,"abstract":"\u0000Purpose\u0000The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved geometric versatility over traditional chiral honeycombs. This paper aims to design and manufacture chiral honeycombs representative of four distinct classes of 2D Euclidean tessellations with hexagonal rotational symmetry using fused-deposition additive manufacturing and experimentally analysed the mechanical properties and failure modes of these metamaterials.\u0000\u0000\u0000Design/methodology/approach\u0000Finite Element simulations were also used to study the high-strain compressive performance of these systems under both periodic boundary conditions and realistic, finite conditions. Experimental uniaxial compressive loading tests were applied to additively manufactured prototypes and digital image correlation was used to measure the Poisson’s ratio and analyse the deformation behaviour of these systems.\u0000\u0000\u0000Findings\u0000The results obtained demonstrate that these systems have the ability to exhibit a wide range of Poisson’s ratios (positive, quasi-zero and negative values) and stiffnesses as well as unusual failure modes characterised by a sequential layer-by-layer collapse of specific, non-adjacent ligaments. These findings provide useful insights on the mechanical properties and deformation behaviours of this new class of metamaterials and indicate that these chiral honeycombs could potentially possess anomalous characteristics which are not commonly found in traditional chiral metamaterials based on regular monohedral tilings.\u0000\u0000\u0000Originality/value\u0000To the best of the authors’ knowledge, the authors have analysed for the first time the high strain behaviour and failure modes of chiral metamaterials based on Euclidean multi-polygonal tessellations.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"161 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140422113","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 : 2024-02-21DOI: 10.1108/rpj-05-2023-0161
Mohan Kumar K, Arumaikkannu G
Purpose The purpose of this paper is to compare the influence of relative density (RD) and strain rates on failure mechanism and specific energy absorption (SEA) of polyamide lattices ranging from bending to stretch-dominated structures using selective laser sintering (SLS). Design/methodology/approach Three bending and two stretch-dominated unit cells were selected based on the Maxwell stability criterion. Lattices were designed with three RD and fabricated by SLS technique using PA12 material. Quasi-static compression tests with three strain rates were carried out using Taguchi's L9 experiments. The lattice compressive behaviour was verified with the Gibson–Ashby analytical model. Findings It has been observed that RD and strain rates played a vital role in lattice compressive properties by controlling failure mechanisms, resulting in distinct post-yielding responses as fluctuating and stable hardening in the plateau region. Analysis of variance (ANOVA) displayed the significant impact of RD and emphasised dissimilar influences of strain rate that vary to cell topology. Bending-dominated lattices showed better compressive properties than stretch-dominated lattices. The interesting observation is that stretch-dominated lattices with over-stiff topology exhibited less compressive properties contrary to the Maxwell stability criterion, whereas strain rate has less influence on the SEA of face-centered and body-centered cubic unit cells with vertical and horizontal struts (FBCCXYZ). Practical implications This comparative study is expected to provide new prospects for designing end-user parts that undergo various impact conditions like automotive bumpers and evolving techniques like hybrid and functionally graded lattices. Originality/value To the best of the authors' knowledge, this is the first work that relates the strain rate with compressive properties and also highlights the lattice behaviour transformation from ductile to brittle while the increase of RD and strain rate analytically using the Gibson–Ashby analytical model.
{"title":"Quasi-static compression and energy absorption behaviour of polymeric selective laser sintered open cell lattices under varying relative densities","authors":"Mohan Kumar K, Arumaikkannu G","doi":"10.1108/rpj-05-2023-0161","DOIUrl":"https://doi.org/10.1108/rpj-05-2023-0161","url":null,"abstract":"\u0000Purpose\u0000The purpose of this paper is to compare the influence of relative density (RD) and strain rates on failure mechanism and specific energy absorption (SEA) of polyamide lattices ranging from bending to stretch-dominated structures using selective laser sintering (SLS).\u0000\u0000\u0000Design/methodology/approach\u0000Three bending and two stretch-dominated unit cells were selected based on the Maxwell stability criterion. Lattices were designed with three RD and fabricated by SLS technique using PA12 material. Quasi-static compression tests with three strain rates were carried out using Taguchi's L9 experiments. The lattice compressive behaviour was verified with the Gibson–Ashby analytical model.\u0000\u0000\u0000Findings\u0000It has been observed that RD and strain rates played a vital role in lattice compressive properties by controlling failure mechanisms, resulting in distinct post-yielding responses as fluctuating and stable hardening in the plateau region. Analysis of variance (ANOVA) displayed the significant impact of RD and emphasised dissimilar influences of strain rate that vary to cell topology. Bending-dominated lattices showed better compressive properties than stretch-dominated lattices. The interesting observation is that stretch-dominated lattices with over-stiff topology exhibited less compressive properties contrary to the Maxwell stability criterion, whereas strain rate has less influence on the SEA of face-centered and body-centered cubic unit cells with vertical and horizontal struts (FBCCXYZ).\u0000\u0000\u0000Practical implications\u0000This comparative study is expected to provide new prospects for designing end-user parts that undergo various impact conditions like automotive bumpers and evolving techniques like hybrid and functionally graded lattices.\u0000\u0000\u0000Originality/value\u0000To the best of the authors' knowledge, this is the first work that relates the strain rate with compressive properties and also highlights the lattice behaviour transformation from ductile to brittle while the increase of RD and strain rate analytically using the Gibson–Ashby analytical model.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"20 9","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140444850","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 : 2024-02-21DOI: 10.1108/rpj-08-2023-0289
Seoyeah Oh, Keun Park
Purpose Additive Manufacturing (AM) conventionally necessitates an intermediary slicing procedure using the standard tessellation language (STL) data, which can be computationally burdensome, especially for intricate microcellular architectures. This study aims to propose a direct slicing method tailored for digital light processing-type AM processes for the efficient generation of slicing data for microcellular structures. Design/methodology/approach The authors proposed a direct slicing method designed for microcellular structures, encompassing micro-lattice and triply periodic minimal surface (TPMS) structures. The sliced data of these structures were represented mathematically and then convert into 2D monochromatic images, bypassing the time-consuming slicing procedures required by 3D STL data. The efficiency of the proposed method was validated through data preparations for lattice-based nasopharyngeal swabs and TPMS-based ellipsoid components. Furthermore, its adaptability was highlighted by incorporating 2D images of additional features, eliminating the requirement for complex 3D Boolean operations. Findings The direct slicing method offered significant benefits upon implementation for microcellular structures. For lattice-based nasopharyngeal swabs, it reduced data size by a factor of 1/300 and data preparation time by a factor of 1/8. Similarly, for TPMS-based ellipsoid components, it reduced data size by a factor of 1/60 and preparation time by a factor of 1/16. Originality/value The direct slicing method allows for bypasses the computational burdens associated with traditional indirect slicing from 3D STL data, by directly translating complex cellular structures into 2D sliced images. This method not only reduces data volume and processing time significantly but also demonstrates the versatility of sliced data preparation by integrating supplementary features using 2D operations.
{"title":"Direct slicing of microcellular structures for digital light processing (DLP) additive manufacturing","authors":"Seoyeah Oh, Keun Park","doi":"10.1108/rpj-08-2023-0289","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0289","url":null,"abstract":"\u0000Purpose\u0000Additive Manufacturing (AM) conventionally necessitates an intermediary slicing procedure using the standard tessellation language (STL) data, which can be computationally burdensome, especially for intricate microcellular architectures. This study aims to propose a direct slicing method tailored for digital light processing-type AM processes for the efficient generation of slicing data for microcellular structures.\u0000\u0000\u0000Design/methodology/approach\u0000The authors proposed a direct slicing method designed for microcellular structures, encompassing micro-lattice and triply periodic minimal surface (TPMS) structures. The sliced data of these structures were represented mathematically and then convert into 2D monochromatic images, bypassing the time-consuming slicing procedures required by 3D STL data. The efficiency of the proposed method was validated through data preparations for lattice-based nasopharyngeal swabs and TPMS-based ellipsoid components. Furthermore, its adaptability was highlighted by incorporating 2D images of additional features, eliminating the requirement for complex 3D Boolean operations.\u0000\u0000\u0000Findings\u0000The direct slicing method offered significant benefits upon implementation for microcellular structures. For lattice-based nasopharyngeal swabs, it reduced data size by a factor of 1/300 and data preparation time by a factor of 1/8. Similarly, for TPMS-based ellipsoid components, it reduced data size by a factor of 1/60 and preparation time by a factor of 1/16.\u0000\u0000\u0000Originality/value\u0000The direct slicing method allows for bypasses the computational burdens associated with traditional indirect slicing from 3D STL data, by directly translating complex cellular structures into 2D sliced images. This method not only reduces data volume and processing time significantly but also demonstrates the versatility of sliced data preparation by integrating supplementary features using 2D operations.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"2 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140445146","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}
Purpose This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise involves the utilization of spatially demanding materials for the absorption of sound. These materials lack the ability for targeted frequency control adjustments. Hence, there is a requirement for an approach that can effectively manage low-frequency noise using lightweight and durable materials. Design/methodology/approach The CAD model was created in SolidWorks and was manufactured using the Digital Light Processing (DLP) 3D printing technique. Experimental study and numerical simulations examined the metamaterial’s acoustic absorption. An impedance tube with two microphones was used to determine the absorption coefficient of the metamaterial. The simulations were run in a thermoviscous module. Findings The testing of acoustic samples highlighted the effects of geometric parameters on acoustic performance. Increment of the strut length by 0.4 mm led to a shift in response to a lower frequency by 500 Hz. Peak absorption rose from 0.461 to 0.690 as the strut diameter was increased from 0.6 to 1.0 mm. Increasing the number of cells from 8 to 20 increased the absorption coefficient and lowered the response frequency. Originality/value DLP 3D printing technique was used to successfully manufacture tetrakaidecahedron-based acoustic metamaterial samples. A novel study on the effects of geometric parameters of tetrakaidecahedron cell-based acoustic metamaterial on the acoustic absorption coefficient was conducted, which seemed to be missing in the literature.
{"title":"Sound absorption advancements: exploring 3D printing in the development of tetrakaidecahedron cell-based acoustic metamaterials","authors":"Saliq Shamim Shah, Daljeet Singh, Jaswinder Singh Saini, Naveen Garg","doi":"10.1108/rpj-08-2023-0304","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0304","url":null,"abstract":"\u0000Purpose\u0000This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise involves the utilization of spatially demanding materials for the absorption of sound. These materials lack the ability for targeted frequency control adjustments. Hence, there is a requirement for an approach that can effectively manage low-frequency noise using lightweight and durable materials.\u0000\u0000\u0000Design/methodology/approach\u0000The CAD model was created in SolidWorks and was manufactured using the Digital Light Processing (DLP) 3D printing technique. Experimental study and numerical simulations examined the metamaterial’s acoustic absorption. An impedance tube with two microphones was used to determine the absorption coefficient of the metamaterial. The simulations were run in a thermoviscous module.\u0000\u0000\u0000Findings\u0000The testing of acoustic samples highlighted the effects of geometric parameters on acoustic performance. Increment of the strut length by 0.4 mm led to a shift in response to a lower frequency by 500 Hz. Peak absorption rose from 0.461 to 0.690 as the strut diameter was increased from 0.6 to 1.0 mm. Increasing the number of cells from 8 to 20 increased the absorption coefficient and lowered the response frequency.\u0000\u0000\u0000Originality/value\u0000DLP 3D printing technique was used to successfully manufacture tetrakaidecahedron-based acoustic metamaterial samples. A novel study on the effects of geometric parameters of tetrakaidecahedron cell-based acoustic metamaterial on the acoustic absorption coefficient was conducted, which seemed to be missing in the literature.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"322 5","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139834721","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}
Purpose This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise involves the utilization of spatially demanding materials for the absorption of sound. These materials lack the ability for targeted frequency control adjustments. Hence, there is a requirement for an approach that can effectively manage low-frequency noise using lightweight and durable materials. Design/methodology/approach The CAD model was created in SolidWorks and was manufactured using the Digital Light Processing (DLP) 3D printing technique. Experimental study and numerical simulations examined the metamaterial’s acoustic absorption. An impedance tube with two microphones was used to determine the absorption coefficient of the metamaterial. The simulations were run in a thermoviscous module. Findings The testing of acoustic samples highlighted the effects of geometric parameters on acoustic performance. Increment of the strut length by 0.4 mm led to a shift in response to a lower frequency by 500 Hz. Peak absorption rose from 0.461 to 0.690 as the strut diameter was increased from 0.6 to 1.0 mm. Increasing the number of cells from 8 to 20 increased the absorption coefficient and lowered the response frequency. Originality/value DLP 3D printing technique was used to successfully manufacture tetrakaidecahedron-based acoustic metamaterial samples. A novel study on the effects of geometric parameters of tetrakaidecahedron cell-based acoustic metamaterial on the acoustic absorption coefficient was conducted, which seemed to be missing in the literature.
{"title":"Sound absorption advancements: exploring 3D printing in the development of tetrakaidecahedron cell-based acoustic metamaterials","authors":"Saliq Shamim Shah, Daljeet Singh, Jaswinder Singh Saini, Naveen Garg","doi":"10.1108/rpj-08-2023-0304","DOIUrl":"https://doi.org/10.1108/rpj-08-2023-0304","url":null,"abstract":"\u0000Purpose\u0000This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise involves the utilization of spatially demanding materials for the absorption of sound. These materials lack the ability for targeted frequency control adjustments. Hence, there is a requirement for an approach that can effectively manage low-frequency noise using lightweight and durable materials.\u0000\u0000\u0000Design/methodology/approach\u0000The CAD model was created in SolidWorks and was manufactured using the Digital Light Processing (DLP) 3D printing technique. Experimental study and numerical simulations examined the metamaterial’s acoustic absorption. An impedance tube with two microphones was used to determine the absorption coefficient of the metamaterial. The simulations were run in a thermoviscous module.\u0000\u0000\u0000Findings\u0000The testing of acoustic samples highlighted the effects of geometric parameters on acoustic performance. Increment of the strut length by 0.4 mm led to a shift in response to a lower frequency by 500 Hz. Peak absorption rose from 0.461 to 0.690 as the strut diameter was increased from 0.6 to 1.0 mm. Increasing the number of cells from 8 to 20 increased the absorption coefficient and lowered the response frequency.\u0000\u0000\u0000Originality/value\u0000DLP 3D printing technique was used to successfully manufacture tetrakaidecahedron-based acoustic metamaterial samples. A novel study on the effects of geometric parameters of tetrakaidecahedron cell-based acoustic metamaterial on the acoustic absorption coefficient was conducted, which seemed to be missing in the literature.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"79 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139774914","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 : 2024-02-09DOI: 10.1108/rpj-02-2023-0047
Martin Novák, B. Hausnerova, V. Pata, Daniel Sanétrník
Purpose This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS). Design/methodology/approach PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools. Findings Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route. Originality/value This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.
{"title":"On the possibilities of merging additive manufacturing and powder injection molding in the production of metal parts","authors":"Martin Novák, B. Hausnerova, V. Pata, Daniel Sanétrník","doi":"10.1108/rpj-02-2023-0047","DOIUrl":"https://doi.org/10.1108/rpj-02-2023-0047","url":null,"abstract":"\u0000Purpose\u0000This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).\u0000\u0000\u0000Design/methodology/approach\u0000PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.\u0000\u0000\u0000Findings\u0000Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.\u0000\u0000\u0000Originality/value\u0000This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":" 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139790193","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 : 2024-02-09DOI: 10.1108/rpj-02-2023-0047
Martin Novák, B. Hausnerova, V. Pata, Daniel Sanétrník
Purpose This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS). Design/methodology/approach PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools. Findings Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route. Originality/value This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.
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Pub Date : 2024-02-01DOI: 10.1108/rpj-03-2023-0105
S. Pattanayak, S. Sahoo, A. K. Sahoo, R. Vinjamuri, P. Dwivedi
Purpose This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire. Design/methodology/approach The effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on bead characteristics is studied through response surface methodology (RSM). Under optimum deposition condition, a single-bead and thin-layered part is fabricated and subjected to microstructural, tensile testing and X-ray diffraction study. Moreover, bulk texture analysis has been carried out to illustrate the effect of thermal cycles and tensile-induced deformations on fibre texture evolutions. Findings RSM illustrates WFS as a crucial deposition parameter that suitably monitors bead width, height, penetration depth, dilution, contact angle and microhardness. The ferritic (acicular and polygonal) and lath bainitic microstructure is transformed into ferrite and pearlitic micrographs with increasing deposition layers. It is attributed to a reduced cooling rate with increased depositions. Mechanical testing exhibits high tensile strength and ductility, which is primarily due to compressive residual stress and lattice strain development. In deposits, ϒ-fibre evolution is more resilient due to the continuous recrystallisation process after each successive deposition. Tensile-induced deformation mostly favours ζ and ε-fibre development due to high strain accumulations. Originality/value This modified electrode arrangement in NTA-WAM suitably reduces spatter and bead height deviation. Low penetration depth and dilution denote a reduction in heat input that enhances the cooling rate.
目的本研究旨在展示一种改良的线弧增材制造（AM）方法，命名为非转移电弧和线弧增材制造（NTA-WAM）。设计/方法/途径通过响应面方法学（RSM）研究了各种熔敷条件（焊接电压、移动速度和送丝速度 [WFS]）对焊珠特性的影响。在最佳沉积条件下，制作了单珠薄层部件，并对其进行了微观结构、拉伸测试和 X 射线衍射研究。此外，还进行了块状纹理分析，以说明热循环和拉伸引起的变形对纤维纹理演变的影响。研究结果RSM 表明，WFS 是一个关键的沉积参数，可适当监测珠子的宽度、高度、渗透深度、稀释度、接触角和显微硬度。随着沉积层数的增加，铁素体（针状和多角形）和板条贝氏体微观结构转变为铁素体和珠光体微观结构。这是因为随着沉积层的增加，冷却速度降低。机械测试显示出较高的拉伸强度和延展性，这主要是由于压缩残余应力和晶格应变的发展。在沉积过程中，ϒ纤维的演变更具弹性，这是因为每次连续沉积后都会发生连续的再结晶过程。由于高应变累积，拉伸引起的变形主要有利于 ζ 和 ε 纤维的发展。低穿透深度和稀释意味着热输入的减少，从而提高了冷却速度。
{"title":"Non-transferring arc and wire additive manufacturing: microstructure, mechanical properties and bulk texture evolution of deposits","authors":"S. Pattanayak, S. Sahoo, A. K. Sahoo, R. Vinjamuri, P. Dwivedi","doi":"10.1108/rpj-03-2023-0105","DOIUrl":"https://doi.org/10.1108/rpj-03-2023-0105","url":null,"abstract":"\u0000Purpose\u0000This study aims to demonstrate a modified wire arc additive manufacturing (AM) named non-transferring arc and wire AM (NTA-WAM). Here, the build plate has no electrical arc attachment, and the system’s arc is ignited between tungsten electrode and filler wire.\u0000\u0000\u0000Design/methodology/approach\u0000The effect of various deposition conditions (welding voltage, travel speed and wire feed speed [WFS]) on bead characteristics is studied through response surface methodology (RSM). Under optimum deposition condition, a single-bead and thin-layered part is fabricated and subjected to microstructural, tensile testing and X-ray diffraction study. Moreover, bulk texture analysis has been carried out to illustrate the effect of thermal cycles and tensile-induced deformations on fibre texture evolutions.\u0000\u0000\u0000Findings\u0000RSM illustrates WFS as a crucial deposition parameter that suitably monitors bead width, height, penetration depth, dilution, contact angle and microhardness. The ferritic (acicular and polygonal) and lath bainitic microstructure is transformed into ferrite and pearlitic micrographs with increasing deposition layers. It is attributed to a reduced cooling rate with increased depositions. Mechanical testing exhibits high tensile strength and ductility, which is primarily due to compressive residual stress and lattice strain development. In deposits, ϒ-fibre evolution is more resilient due to the continuous recrystallisation process after each successive deposition. Tensile-induced deformation mostly favours ζ and ε-fibre development due to high strain accumulations.\u0000\u0000\u0000Originality/value\u0000This modified electrode arrangement in NTA-WAM suitably reduces spatter and bead height deviation. Low penetration depth and dilution denote a reduction in heat input that enhances the cooling rate.\u0000","PeriodicalId":509442,"journal":{"name":"Rapid Prototyping Journal","volume":"10 13","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139684305","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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