From Conventional to Additive Manufacturing: Determining Component Fabrication Feasibility

2018 ◽  
Author(s):  
Seyedeh Elaheh Ghiasian ◽  
Prakhar Jaiswal ◽  
Rahul Rai ◽  
Kemper Lewis
Keyword(s):  
Additive Manufacturing ◽  
Economic Feasibility ◽  
The Core ◽  
Industrial Grade ◽  
Wide Range ◽  
Subtractive Manufacturing ◽  
Continuous Objects ◽  
Manufacturing Techniques ◽  
Primary Assessment ◽  
Core Functionality

The use of additive manufacturing (AM) for fabricating industrial grade components has increased significantly in recent years. Numerous industrial entities are looking to leverage new AM techniques to enable fabrication of components that were typically manufactured previously using conventional manufacturing techniques such as subtractive manufacturing or casting. Therefore, it is becoming increasingly important to be able to rigorously evaluate the technical and economic feasibility of additively manufacturing a component relative to conventional alternatives. In order to support this evaluation, this paper presents a framework that investigates fabrication feasibility for AM from three perspectives: geometric evaluation, build orientation/support generation, and resources necessary (i.e., cost and time). The core functionality of the framework is enabled on voxelized model representation, discrete and binary formats of 3D continuous objects. AM fabrication feasibility analysis is applied to 34 various parts representing a wide range of manifolds and valves manufactured using conventional manufacturing techniques, components commonly found in the aerospace industry. Results obtained illustrate the capability and generalizability of the framework to analyze intricate geometries and provide a primary assessment for the feasibility of the AM process.

scholarly journals Fatigue Cracking of Additively Manufactured Materials—Process and Material Perspectives

2020 ◽  
Vol 10 (16) ◽  
pp. 5556
Author(s):  
Torsten Fischer ◽  
Bernd Kuhn ◽  
Detlef Rieck ◽  
Axel Schulz ◽  
Ralf Trieglaff ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Fatigue Strength ◽  
Process Control ◽  
High Performance ◽  
Chemical Engineering ◽  
Fatigue Cracking ◽  
Metal Powders ◽  
Wide Range ◽  
Manufacturing Techniques ◽  
The Impact

Strong efforts are made internationally to optimize the process control of laser additive manufacturing processes. For this purpose, advanced detectors and monitoring software are being developed to control the quality of production. However, commercial suppliers of metal powders and part manufacturers are essentially focused on well-established materials. This article demonstrates the potential of optimized process control. Furthermore, we outline the development of a new high temperature structural steel, tailored to best utilize the advantages of additive manufacturing techniques. In this context, the impact of production-induced porosity on fatigue strength of austenitic 316L is presented. Additionally, we discuss the first conceptual results of a novel ferritic steel, named HiperFer (High Performance Ferrite), which was designed for increased fatigue strength. This ferritic, Laves phase-strengthened, stainless steel could be used for a wide range of structural components in power and (petro)chemical engineering at maximum temperatures ranging from about 580 to 650 °C. This material benefits from in situ heat treatment and counteracts process-related defects by “reactive” crack obstruction mechanisms, hampering both crack initiation and crack propagation. In this way, increased fatigue resistance and safety can be achieved.

Multiscale Modeling of the Laser Additive Manufacturing Process

2020 ◽  
pp. 235-248
Author(s):  
Seshadev Sahoo ◽  
Jyotirmoy Nandy
Keyword(s):  
Additive Manufacturing ◽  
Multiscale Modeling ◽  
Manufacturing Sector ◽  
Layer By Layer ◽  
Waste Production ◽  
Detailed Classification ◽  
Wide Range ◽  
Manufacturing Techniques ◽  
The Many ◽  
Efficient Manufacturing

Additive manufacturing (AM) has emerged as the most versatile process in the manufacturing sector. The advantages of AM such as applicability in a wide range of industries, ease of manufacturing, and reduction in waste production have increased its demand over the past decades. Out of the many techniques under AM, direct metal laser sintering (DMLS) is one of the most efficient manufacturing techniques that uses a high-powered laser beam to sinter metal powders in a layer-by-layer fashion. With the current usage of computational modeling, the prediction of microstructure evolution and other thermo-mechanical properties of different materials have been of great advantage to researchers. Along with a detailed classification of AM techniques, this chapter focuses on the use of continuum, phase field, and atomistic modeling under the DMLS process. The results show that multiscale modeling can be advantageous in gaining deeper insight into various phenomena like diffusion and sintering.

A Preference-Based Approach to Assess a Component’s Design Readiness for Additive Manufacturing

2020 ◽  
Vol 142 (8) ◽  
Author(s):  
Seyedeh Elaheh Ghiasian ◽  
Prakhar Jaiswal ◽  
Rahul Rai ◽  
Kemper Lewis
Keyword(s):  
Decision Support ◽  
Additive Manufacturing ◽  
Experimental Validation ◽  
Economic Benefits ◽  
Economic Feasibility ◽  
Feasibility Analysis ◽  
Component Design ◽  
Subtractive Manufacturing ◽  
Preference Models

Abstract Due to the benefits associated with additive manufacturing (AM), there are increasingly more opportunities to leverage AM to enable the fabrication of components that were previously made using conventional techniques such as subtractive manufacturing or casting. To support this transition, it is critical to be able to rigorously evaluate the technical and economic feasibility of additively manufacturing an existing component design. In order to support this evaluation, this paper presents a novel feasibility analysis that performs a multi-criteria assessment of AM readiness. Along with the development of these assessments, we also present a novel scoring approach for qualitatively and quantitatively evaluating the feasibility of each component assessment. This scoring approach, which leverages preference models from physical programing, introduces a flexible set of feasibility levels to assess the manufacturability capabilities of AM technologies. It also allows for the integration of a designer’s preferences toward the AM assessments, supporting the decision whether to utilize AM technologies or not. The presented feasibility analysis allows for both technical and economic benefits since it suggests only using AM for those products whose feasibility results are within suitable ranges. The details of the approach are illustrated using four sample parts with varying geometries. Experimental validation is also performed to demonstrate the robustness of the evaluation. Results obtained show the capability and generalizability of these approaches to analyze intricate geometries and provide useful decision support in AM feasibility analysis.

scholarly journals Engineering and Economic Aspects of Additive Manufacturing in Energy Related Industries

2020 ◽  
Author(s):  
Sandip Dutta ◽  
Sagar Dasgupta ◽  
Geetha Chimata
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Production Methods ◽  
Energy Applications ◽  
Recent Developments ◽  
Subtractive Manufacturing ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing ◽  
Am Processes

Additive manufacturing is the buzz word these days and many companies are leaning on this technology to leap forward in un-chartered design space that promises to give better performance at impossible to reach design goals with the current manufacturing methods. This paper addresses recent developments that have occurred in Energy related businesses with the adoption of 3D printing, also known as Additive Manufacturing (AM). It covers what and why of additive manufacturing; what constitutes energy and AM industry; current activities in AM for energy; AM for different energy sectors; AM processes; AM applications; selected patents in additive manufacturing associated with energy applications; and economic and financial aspects of AM in energy related industries. In this review paper it was noted that in-spite of phenomenal growth in AM, it seldom replaces traditional production methods due to associated constraints. Many companies are finding complimentary AM processes along with subtractive manufacturing techniques to meet the market demands. However, AM is particularly advantageous and attractive compared to traditional manufacturing methods for low volume complex geometry parts.

scholarly journals Engineering Thermoplastics for Additive Manufacturing: A Critical Perspective with Experimental Evidence to Support Functional Applications

2017 ◽  
Vol 15 (1) ◽  
pp. 10-18 ◽  
Author(s):  
Gianluca Cicala ◽  
Alberta Latteri ◽  
Barbara Del Curto ◽  
Alessio Lo Russo ◽  
Giuseppe Recca ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Injection Molding ◽  
Fused Deposition Modeling ◽  
Mechanical And Thermal Properties ◽  
Functional Applications ◽  
Fused Deposition ◽  
Industrial Grade ◽  
Raster Angle ◽  
Manufacturing Techniques

Background Among additive manufacturing techniques, the filament-based technique involves what is referred to as fused deposition modeling (FDM). FDM materials are currently limited to a selected number of polymers. The present study focused on investigating the potential of using high-end engineering polymers in FDM. In addition, a critical review of the materials available on the market compared with those studied here was completed. Methods Different engineering thermoplastics, ranging from industrial grade polycarbonates to novel polyetheretherketones (PEEKs), were processed by FDM. Prior to this, for innovative filaments based on PEEK, extrusion processing was carried out. Mechanical properties (i.e., tensile and flexural) were investigated for each extruded material. An industrial-type FDM machine (Stratasys Fortus® 400 mc) was used to fully characterize the effect of printing parameters on the mechanical properties of polycarbonate. The obtained properties were compared with samples obtained by injection molding. Finally, FDM samples made of PEEK were also characterized and compared with those obtained by injection molding. Results The effect of raster to raster air gap and raster angle on tensile and flexural properties of printed PC was evidenced; the potential of PEEK filaments, as novel FDM material, was highlighted in comparison to state of the art materials. Conclusions Comparison with injection molded parts allowed to better understand FDM potential for functional applications. The study discussed pros and cons of the different materials. Finally, the development of novel PEEK filaments achieved important results offering a novel solution to the market when high mechanical and thermal properties are required.

scholarly journals An Additive Manufacturing Method Using Large-Scale Wood Inspired by Laminated Object Manufacturing and Plywood Technology

Polymers ◽  
2020 ◽  
Vol 13 (1) ◽  
pp. 144
Author(s):  
Yubo Tao ◽  
Qing Yin ◽  
Peng Li
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Complex Geometries ◽  
Layer Height ◽  
Manufacturing Method ◽  
Laminated Object Manufacturing ◽  
Subtractive Manufacturing ◽  
Manufacturing Techniques ◽  
Further Development ◽  
Thickness Layer

Wood-based materials in current additive manufacturing (AM) feedstocks are primarily restricted to the micron scale. Utilizing large-scale wood in existing AM techniques remains a challenge. This paper proposes an AM method—laser-cut veneer lamination (LcVL)—for wood-based product fabrication. Inspired by laminated object manufacturing (LOM) and plywood technology, LcVL bonds wood veneers in a layer-upon-layer manner. As demonstrated by printed samples, LcVL was able to retain the advantageous qualities of AM, specifically, the ability to manufacture products with complex geometries which would otherwise be impossible using subtractive manufacturing techniques. Furthermore, LcVL-product structures designed through adjusting internal voids and wood-texture directionality could serve as material templates or matrices for functional wood-based materials. Numerical analyses established relations between the processing resolution of LcVL and proportional veneer thickness (layer height). LcVL could serve as a basis for the further development of large-scale wood usage in AM.

Development of Novel Hybrid Manufacturing Technique for Manufacturing Support Structures Free Complex Parts

2019 ◽  
Author(s):  
Haris Ali Khan ◽  
Toyosi Ademujimi
Keyword(s):  
Additive Manufacturing ◽  
Support Structures ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Novel Approach ◽  
Subtractive Manufacturing ◽  
Need For Support ◽  
Near Net Shape ◽  
Manufacturing Techniques ◽  
Complex Parts

Abstract This study unearths a novel approach utilizing conventional subtractive manufacturing technology (5-axis CNC milling center) to realize additively manufactured complex geometries without employing support structures. The proposed approach was based on benefiting from the precision and accuracy of subtractive manufacturing while leveraging the freedom of design of additive manufacturing (AM) process. The desired objectives were achieved in a three-stepped methodology where initially the CNC machine was modified to adapt the 3D printing protocols while in the second step, additional hardware was retrofitted on the conventional CNC machine making it compatible to print 3D parts. A “geometric subsection” approach was adopted as the third step where the desired printed part was divided in different subsections based on the overhang angles and the rotational axes of the CNC machine was then utilized in a manner to eliminate the need for support structures. The manufactured AM part can then be post-processed employing the same machining platform. The proposed approach thereby also served as a next step in evolution of done-in-one processes by printing near-net shape components through additive manufacturing and then promptly acquiring the net shape through subtractive manufacturing techniques.

Additive Manufacturing Sustainability in Industries

2020 ◽  
Vol 12 (7) ◽  
pp. 894-899
Author(s):  
Devendra Kumar Prajapati ◽  
Ravinder Kumar
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Complex Shape ◽  
Three Dimensional ◽  
Core Knowledge ◽  
Research Papers ◽  
Advanced Technique ◽  
The Core ◽  
Wide Range ◽  
Dimensional Object

Additive manufacturing (AM) is an advanced technique to fabricate a three-dimensional object while utilizing materials with minimal wastage to produce complex shape geometries. This technique has escalated practically as well as academically, resulting in a wide range of utility in the current global scenario to ease the manufacturing of complex and intricate objects with the use of various materials, depending upon the properties and availability of the same. Every industries wants to achieve the sustainability, easily can be possible through this manufacturing process. Due to the scope for a large number of design, material and processing combinations, a detailed outlook to how additive manufacturing can be optimized for a highly sustainable and standardized manufacturing practice needs to be assessed and understood. This paper discusses the core knowledge available regarding this manufacturing process and highlights the different processes related to this technique through review of various research papers. And also discuss the sustainability of important additive manufacturing process. Along with the fundamental analysis of this process, the paper also discusses the various attributes of the process and the growth with respect to the latest trends and techniques currently used in industries.

Duoethnography: A Polytheoretical Approach to (Re)Storing, (Re)Storying the Meanings That One Gives

2020 ◽  
pp. 396-423
Author(s):  
John Joseph Norris ◽  
Richard D. Sawyer
Keyword(s):  
Social Justice ◽  
Critical Theory ◽  
Third Space ◽  
The Third ◽  
The Core ◽  
Wide Range ◽  
Core Elements ◽  
Feminist Inquiry

This chapter summarizes the advancement of duoethnography throughout its fifteen-year history, employing examples from a variety of topics in education and social justice to provide a wide range of approaches that one may take when conducting a duoethnography. A checklist articulates what its cofounders consider the core elements of duoethnographies, additional features that may or may not be employed and how some studies purporting to be duoethnographies may not be so. The chapter indicates connections between duoethnography and a number of methodological concepts including the third space, the problematics of representation, feminist inquiry, and critical theory using published examples by several duoethnographers.

scholarly journals A Review on Additive Manufacturing Possibilities for Electrical Machines

Energies ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1940
Author(s):  
Muhammad Usman Naseer ◽  
Ants Kallaste ◽  
Bilal Asad ◽  
Toomas Vaimann ◽  
Anton Rassõlkin
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Three Dimensional ◽  
Electrical Machines ◽  
Electromagnetic Properties ◽  
Scale Production ◽  
Performance Parameters ◽  
Large Scale Production ◽  
One Step ◽  
Manufacturing Techniques

This paper presents current research trends and prospects of utilizing additive manufacturing (AM) techniques to manufacture electrical machines. Modern-day machine applications require extraordinary performance parameters such as high power-density, integrated functionalities, improved thermal, mechanical & electromagnetic properties. AM offers a higher degree of design flexibility to achieve these performance parameters, which is impossible to realize through conventional manufacturing techniques. AM has a lot to offer in every aspect of machine fabrication, such that from size/weight reduction to the realization of complex geometric designs. However, some practical limitations of existing AM techniques restrict their utilization in large scale production industry. The introduction of three-dimensional asymmetry in machine design is an aspect that can be exploited most with the prevalent level of research in AM. In order to take one step further towards the enablement of large-scale production of AM-built electrical machines, this paper also discusses some machine types which can best utilize existing developments in the field of AM.

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