Numerical Simulation of Random Packing of Spherical Particles for Powder-Based Additive Manufacturing

2009 ◽  
Vol 131 (3) ◽  
Author(s):  
Jianhua Zhou ◽  
Yuwen Zhang ◽  
J. K. Chen
Keyword(s):  
Additive Manufacturing ◽  
Pair Distribution Function ◽  
Random Packing ◽  
Spherical Particles ◽  
Rapid Manufacturing ◽  
Manufacturing Processes ◽  
Packing Structure ◽  
Sequential Addition ◽  
Traditional Manufacturing ◽  
Complex Parts

Powder-based additive manufacturing is an efficient and rapid manufacturing technique because it allows fabrication of complex parts that are often unobtainable by traditional manufacturing processes. A better understanding of the packing structure of the powder is urgently needed for the powder-based additive manufacturing. In this study, the sequential addition packing algorithm is employed to investigate the random packing of spherical particles with and without shaking effect. The 3D random packing structures are demonstrated by illustrative pictures and quantified in terms of pair distribution function, coordination number, and packing density. The results are presented and discussed aiming to produce the desirable packing structures for powder-based additive manufacturing.

Numerical Simulation of Random Packing of Spherical Particles for Selective Laser Sintering Applications

2008 ◽  
Author(s):  
Jianhua Zhou ◽  
Yuwen Zhang ◽  
J. K. Chen
Keyword(s):  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Random Packing ◽  
Spherical Particles ◽  
Structural Defects ◽  
Optimal Packing ◽  
Packing Structure ◽  
Sequential Addition ◽  
Traditional Manufacturing ◽  
Complex Parts

Selective Laser Sintering (SLS) is an efficient and rapid manufacturing technique because it allows for making complex parts that are often unobtainable by traditional manufacturing processes. However, the application of such technique is quite limited by the balling phenomenon, for which it largely reduces the manufacturing quality. Eliminating the structural defects is crucial to overcome the balling phenomenon. Therefore, a better understanding of the packing structure details is urgently needed for the SLS applications. In this study, the sequential addition packing algorithm is employed to investigate the random packing of spherical particles with and without shaking effect. The 3-D random packing structures are demonstrated by illustrative pictures and quantified in terms of pair distribution function, coordination number and packing density. The results are presented and discussed aiming to produce the optimal packing parameters for the SLS manufacturing process.

Laser Additive Manufacturing in Surface Modification of Metals

3D Printing ◽  
2017 ◽  
pp. 183-203
Author(s):  
Rasheedat M. Mahamood ◽  
Mukul Shukla ◽  
Sisa Pityana
Keyword(s):  
Surface Modification ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Manufacturing Processes ◽  
Laser Additive Manufacturing ◽  
Material Deposition ◽  
Traditional Manufacturing ◽  
Titanium Alloy Ti6al4v ◽  
High Flexibility ◽  
Complex Parts

Additive Manufacturing (AM) offers lots of advantages when compared to other manufacturing processes, such as high flexibility and ability to produce complex parts directly from the Three Dimensional (3D) Computer-Aided Design (CAD) model. Producing highly complex parts using traditional manufacturing processes is difficult, and it requires it to be broken down into smaller parts, which consumes lots of materials and time. If this part needs to have a surface with improved property or a surface made of composite materials, it has to be done by employing another manufacturing process after the parts are completed. AM, on the other hand, has the ability to produce parts with the required surface property in a single manufacturing run. Out of all the AM technologies, Laser Additive Manufacturing (LAM) is the most commonly used technique, especially for metal processing. LAM uses the coherent and collimated properties of the laser beam to fuse, melt, or cut materials according to the profile generated from the CAD image of the part being made. Some of the LAM techniques and their mode of operations are highlighted in this chapter. The capabilities of using LAM for surface modification of metals are also presented in this chapter. A specific example is given as a case study for the surface modification of titanium alloy (Ti6Al4V) with Ti6Al4V/TiC composite using laser material deposition process – an important LAM technology. Ti6Al4V is an important aerospace alloy, and it is also used as medical implants because of its corrosion resistance property and its biocompatibility.

Laser Additive Manufacturing in Surface Modification of Metals

2014 ◽  
pp. 222-248 ◽  
Author(s):  
Rasheedat M. Mahamood ◽  
Mukul Shukla ◽  
Sisa Pityana
Keyword(s):  
Surface Modification ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Manufacturing Processes ◽  
Laser Additive Manufacturing ◽  
Material Deposition ◽  
Traditional Manufacturing ◽  
Titanium Alloy Ti6al4v ◽  
High Flexibility ◽  
Complex Parts

Additive Manufacturing (AM) offers lots of advantages when compared to other manufacturing processes, such as high flexibility and ability to produce complex parts directly from the Three Dimensional (3D) Computer-Aided Design (CAD) model. Producing highly complex parts using traditional manufacturing processes is difficult, and it requires it to be broken down into smaller parts, which consumes lots of materials and time. If this part needs to have a surface with improved property or a surface made of composite materials, it has to be done by employing another manufacturing process after the parts are completed. AM, on the other hand, has the ability to produce parts with the required surface property in a single manufacturing run. Out of all the AM technologies, Laser Additive Manufacturing (LAM) is the most commonly used technique, especially for metal processing. LAM uses the coherent and collimated properties of the laser beam to fuse, melt, or cut materials according to the profile generated from the CAD image of the part being made. Some of the LAM techniques and their mode of operations are highlighted in this chapter. The capabilities of using LAM for surface modification of metals are also presented in this chapter. A specific example is given as a case study for the surface modification of titanium alloy (Ti6Al4V) with Ti6Al4V/TiC composite using laser material deposition process – an important LAM technology. Ti6Al4V is an important aerospace alloy, and it is also used as medical implants because of its corrosion resistance property and its biocompatibility.

vELECTROPLATING POLYMER BASED ADDITIVE MANUFACTURED PARTS FOR ENHANCED STRUCTURAL PERFORMANCE

2021 ◽  
Author(s):  
WARUNA SENEVIRATNE, ◽  
JOHN TOMBLIN ◽  
BRANDON SAATHOFF
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Thickness Variation ◽  
Manufacturing Processes ◽  
Fused Deposition ◽  
Aerospace Applications ◽  
Electroplated Coating ◽  
Traditional Manufacturing ◽  
Plastic Parts ◽  
Subtractive Machining

Additive manufacturing has been adopted in many aerospace and defense applications to reduce weight and buy-to-fly ratios of low-volume high- complexity parts. Polymer-based additive manufacturing processes such as Fused Deposition Modeling (FDM) has enabled aerospace manufactures to improve the structural efficiency of parts through generative design or topology optimization. This level of design freedom did not exist in the past due to limitations associated with traditional manufacturing processes such as subtractive machining. Improvements in the material and the maturation of the FDM process has led to the production of many non-structural flightworthy parts used in aircraft today. Polymer-based additive manufacturing can be further leveraged in aerospace applications with the addition of electroplated coatings that act as reinforcement. While many of the commonly known electroplated coating applications involve enhancing the part appearance, electroplated coatings can also improve the strength, stiffness, and durability of plastic parts. Depending on the use case, the thickness of the metallic plating material (combination of copper and nickel) can be tailored to achieve the desired composite properties (metal and polymer). In this research, the tensile and flexural mechanical properties were assessed for Ultem™ 9085 FDM printed specimens and compared to specimens with metallic coating thicknesses of approximately 75-μm, 150-μm, and 300-μm. Non- destructive inspections using x-ray computed tomography were performed prior to mechanical testing to assess the electroplated coating thickness variation and overall quality.

scholarly journals Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM)

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 766 ◽  
Author(s):  
Fernando Veiga ◽  
Alain Gil Del Val ◽  
Alfredo Suárez ◽  
Unai Alonso
Keyword(s):  
Additive Manufacturing ◽  
Arc Welding ◽  
Machine Tools ◽  
Optimal Strategies ◽  
Machining Process ◽  
Manufacturing Processes ◽  
Plasma Arc Welding ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing

In the current days, the new range of machine tools allows the production of titanium alloy parts for the aeronautical sector through additive technologies. The quality of the materials produced is being studied extensively by the research community. This new manufacturing paradigm also opens important challenges such as the definition and analysis of the optimal strategies for finishing-oriented machining in this type of part. Researchers in both materials and manufacturing processes are making numerous advances in this field. This article discusses the analysis of the production and subsequent machining in the quality of TI6Al4V produced by Wire Arc Additive Manufacturing (WAAM), more specifically Plasma Arc Welding (PAW). The promising results observed make it a viable alternative to traditional manufacturing methods.

Incorporating Manufacturing Constraints in Topology Optimization Methods: A Survey

2017 ◽  
Author(s):  
Alok Sutradhar ◽  
Jaejong Park ◽  
Payam Haghighi ◽  
Jacob Kresslein ◽  
Duane Detwiler ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Methods ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Manufacturing Constraints ◽  
Post Processing ◽  
Optimization Framework ◽  
Manufacturing Methods ◽  
Traditional Manufacturing

Topology optimization provides optimized solutions with complex geometries which are often not suitable for direct manufacturing without further steps or post-processing by the designer. There has been a recent progression towards linking topology optimization with additive manufacturing, which is less restrictive than traditional manufacturing methods, but the technology is still in its infancy being costly, time-consuming, and energy inefficient. For applications in automotive or aerospace industries, the traditional manufacturing processes are still preferred and utilized to a far greater extent. Adding manufacturing constraints within the topology optimization framework eliminates the additional design steps of interpreting the topology optimization result and converting it to viable manufacturable parts. Furthermore, unintended but inevitable deviations that occur during manual conversion from the topology optimized result can be avoided. In this paper, we review recent advances to integrate (traditional) manufacturing constraints in the topology optimization process. The focus is on the methods that can create manufacturable and well-defined geometries. The survey will discuss the advantages, limitations, and related challenges of manufacturability in topology optimization.

Additive Manufacturing Process and Their Applications for Green Technology

2019 ◽  
pp. 262-281
Author(s):  
Keshavamurthy R. ◽  
Vijay Tambrallimath ◽  
Prabhakar Kuppahalli ◽  
Sekhar N.
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Raw Materials ◽  
Aerospace Industry ◽  
Green Technology ◽  
Manufacturing Processes ◽  
Additive Process ◽  
Industrial Manufacturing ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Growth of nature is an additive process that gives sustainable existence to the structures developed; on the other hand, traditional manufacturing techniques can be wasteful as they are subtractive. Additive manufacturing produces almost nil waste and accordingly preserves raw materials resulting in cost reduction for the procurement of the same. It will also cut down on the carbon emissions that are usually generated from industrial manufacturing. Additive printed objects are lighter as well, making them more efficient, especially when used in the automobile and aerospace industry. Further, the intrinsic characteristics and the promising merits of additive manufacturing process are expected to provide a solution to improve the sustainability of the process. This chapter comprehensively reports on various additive manufacturing processes and their sustainable applications for green technology. The state of the art, opportunities, and future, related to sustainable applications of additive manufacturing have been presented at length.

scholarly journals Special Issue: The Science and Technology of 3D Printing

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6261
Author(s):  
Tuhin Mukherjee
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Science And Technology ◽  
Three Dimensional ◽  
Manufacturing Processes ◽  
Special Issue ◽  
Three Dimensional Printing ◽  
Popular Method ◽  
Traditional Manufacturing ◽  
Dimensional Printing

Additive manufacturing, commonly known as three-dimensional printing (3D printing), is becoming an increasingly popular method for making components that are difficult to fabricate using traditional manufacturing processes [...]

scholarly journals Analysis of rapid manufacturing—using layer manufacturing processes for production

2003 ◽  
Vol 217 (1) ◽  
pp. 31-39 ◽  
Author(s):  
N Hopkinson ◽  
P Dicknes
Keyword(s):  
Computer Aided Design ◽  
Unit Cost ◽  
Three Dimensional ◽  
Rapid Manufacturing ◽  
Fused Deposition Modelling ◽  
Manufacturing Processes ◽  
Fused Deposition ◽  
Layer Manufacturing ◽  
End Use ◽  
Traditional Manufacturing

Rapid prototyping (RP) technologies that have emerged over the last 15 years are all based on the principle of creating three-dimensional geometries directly from computer aided design (CAD) by stacking two-dimensional profiles on top of each other. To date most RP parts are used for prototyping or tooling purposes; however, in future the majority may be produced as end-use products. The term ‘rapid manufacturing’ in this context uses RP technologies as processes for the production of end-use products. This paper reports findings from a cost analysis that was performed to compare a traditional manufacturing route (injection moulding) with layer manufacturing processes (stereolithography, fused deposition modelling and laser sintering) in terms of the unit cost for parts made in various quantities. The results show that, for some geometries, it is more economical to use layer manufacturing methods than it is to use traditional approaches for production in the thousands.

scholarly journals Predicting Part Mass, Required Support Material, and Build Time via Autoencoded Voxel Patterns

2018 ◽  
Author(s):  
Christopher McComb ◽  
Nicholas Meisel ◽  
T. W. Simpson ◽  
Christian Murphy
Keyword(s):  
Additive Manufacturing ◽  
Lightweight Design ◽  
Manufacturing Processes ◽  
Dimensional Representation ◽  
Skill Levels ◽  
Experience Levels ◽  
Build Time ◽  
Machine Learning Applications ◽  
Traditional Manufacturing ◽  
Low Dimensional

Additive Manufacturing (AM) allows designers to create intricate geometries that were once too complex or expensive to achieve through traditional manufacturing processes. Currently, Design for Additive Manufacturing (DfAM) is restricted to experts in the field, and novices may overlook potentially transformational design potential enabled by AM. This project aims to make DfAM accessible to a broader audience through deep learning, enabling designers of all skill levels to leverage unique AM geometries when creating new designs. To demonstrate such an approach, a database of files was acquired from industry-sponsored AM challenges focused on lightweight design. These files were converted to a voxelized format, which provides more robust information for machine learning applications. Next, an autoencoder was constructed to a low-dimensional representation of the part designs. Finally, that autoencoder was used to construct a deep neural network capable of predicting various DfAM attributes. This work demonstrates a novel foray towards a more extensive DfAM support system that supports designers at all experience levels.

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