scholarly journals Physical Modelling of the Ball-Rolling Processes

Metals ◽  
2019 ◽  
Vol 9 (1) ◽  
pp. 35 ◽  
Author(s):  
Zbigniew Pater ◽  
Janusz Tomczak ◽  
Łukasz Wójcik ◽  
Tomasz Bulzak
Keyword(s):  
Acrylonitrile Butadiene Styrene ◽  
Physical Modelling ◽  
Model Material ◽  
Helical Rolling ◽  
Rolling Mills ◽  
Cross Rolling ◽  
Plastic Forming ◽  
3D Printed ◽  
Manufacturing Accuracy ◽  
Steel Balls

The objective of the article was to present the state of the problem of physical modelling of the hot-working processes with plasticine as the model material. It was stated that the aforementioned method can prove helpful in analyzing complex plastic forming processes such as cross rolling and helical rolling of balls. In order to confirm this hypothesis, an attempt at forming steel balls with diameters of 40 mm (cross rolling) and 57 mm (helical rolling) under laboratory conditions was made. Further on, these processes were conducted in model form using special model rolling mills and 3D printed acrylonitrile butadiene styrene (ABS) tools. The comparison of the test results regarding shape and manufacturing accuracy, as well as force parameters, confirmed the validity of using physical modelling in the investigation of the process of cross rolling and helical rolling of balls.

scholarly journals A Comparative Analysis of the Physical Modelling of Two Methods of Balls Separation

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7126
Author(s):  
Łukasz Wójcik ◽  
Zbigniew Pater ◽  
Tomasz Bulzak ◽  
Janusz Tomczak ◽  
Konrad Lis
Keyword(s):  
Comparative Analysis ◽  
Physical Modelling ◽  
Rolling Process ◽  
Model Material ◽  
Physical Analysis ◽  
Real Process ◽  
Radial Forces ◽  
3D Printed ◽  
Torque Values ◽  
Skew Rolling

The article presents the results of model tests with which a comparative analysis of two methods of ball separation during the skew rolling process was carried out. A verification of the results obtained in the physical modelling process with the results obtained in the real process of skew ball rolling was also carried out. During the physical modelling, the effect of changing the ball separation method on the quality of the products obtained, variations in maximum torque values and maximum radial forces were analyzed. In the case of real tests, the results were verified with the results of physical modelling, in which the surface quality and torque values for one of the tool sets were compared. Physical modelling was used to verify the differences between the two methods of ball separation. Commercial plasticine based on synthetic wax from the manufacturer PRIMO was used as a model material for physical analysis. The plasticine used for testing was cooled to 0 °C and the cooling process took 24 h. The tools used for the physical modelling were 3D printed and the material used was ABS. The method of physical modelling using plasticine as a model material allows for a correct analysis of hot metal forming processes.

scholarly journals Essential work of fracture assessment of acrylonitrile butadiene styrene (ABS) processed via fused filament fabrication additive manufacturing

2021 ◽  
Author(s):  
Pawan Verma ◽  
Jabir Ubaid ◽  
Andreas Schiffer ◽  
Atul Jain ◽  
Emilio Martínez-Pañeda ◽  
...  
Keyword(s):  
Acrylonitrile Butadiene Styrene ◽  
Essential Work ◽  
Fused Filament Fabrication ◽  
Essential Work Of Fracture ◽  
Fracture Properties ◽  
Raster Angle ◽  
3D Printed ◽  
Printing Direction ◽  
Work Of Fracture ◽  
Butadiene Styrene

AbstractExperiments and finite element (FE) calculations were performed to study the raster angle–dependent fracture behaviour of acrylonitrile butadiene styrene (ABS) thermoplastic processed via fused filament fabrication (FFF) additive manufacturing (AM). The fracture properties of 3D-printed ABS were characterized based on the concept of essential work of fracture (EWF), utilizing double-edge-notched tension (DENT) specimens considering rectilinear infill patterns with different raster angles (0°, 90° and + 45/− 45°). The measurements showed that the resistance to fracture initiation of 3D-printed ABS specimens is substantially higher for the printing direction perpendicular to the crack plane (0° raster angle) as compared to that of the samples wherein the printing direction is parallel to the crack (90° raster angle), reporting EWF values of 7.24 kJ m−2 and 3.61 kJ m−2, respectively. A relatively high EWF value was also reported for the specimens with + 45/− 45° raster angle (7.40 kJ m−2). Strain field analysis performed via digital image correlation showed that connected plastic zones existed in the ligaments of the DENT specimens prior to the onset of fracture, and this was corroborated by SEM fractography which showed that fracture proceeded by a ductile mechanism involving void growth and coalescence followed by drawing and ductile tearing of fibrils. It was further shown that the raster angle–dependent strength and fracture properties of 3D-printed ABS can be predicted with an acceptable accuracy by a relatively simple FE model considering the anisotropic elasticity and failure properties of FFF specimens. The findings of this study offer guidelines for fracture-resistant design of AM-enabled thermoplastics. Graphical abstract

scholarly journals On the Post-Processing of 3D-Printed ABS Parts

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1559
Author(s):  
Mohammad Reza Khosravani ◽  
Jonas Schüürmann ◽  
Filippo Berto ◽  
Tamara Reinicke
Keyword(s):  
Surface Treatment ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Tests ◽  
Fracture Load ◽  
Post Processing ◽  
Fused Deposition ◽  
Dog Bone ◽  
3D Printed

Application of Additive Manufacturing (AM) has significantly increased in the past few years. AM also known as three-dimensional (3D) printing has been currently used in fabrication of prototypes and end-use products. Considering the new applications of additively manufactured components, it is necessary to study structural details of these parts. In the current study, influence of a post-processing on the mechanical properties of 3D-printed parts has been investigated. To this aim, Acrylonitrile Butadiene Styrene (ABS) material was used to produce test coupons based on the Fused Deposition Modeling (FDM) process. More in deep, a device was designed and fabricated to fix imperfection and provide smooth surfaces on the 3D-printed ABS specimens. Later, original and treated specimens were subjected to a series of tensile loads, three-point bending tests, and water absorption tests. The experimental tests indicated fracture load in untreated dog-bone shaped specimen was 2026.1 N which was decreased to 1951.7 N after surface treatment. Moreover, the performed surface treatment was lead and decrease in tensile strength from 29.37 MPa to 26.25 MPa. Comparison of the results confirmed effects of the surface modification on the fracture toughness of the examined semi-circular bending components. Moreover, a 3D laser microscope was used for visual investigation of the specimens. The documented results are beneficial for next designs and optimization of finishing processes.

Coupled Thermo-Mechanical FEA of Three-Roll Cross Rolling Process for Rings with Small-Hole and Deep Groove

2012 ◽  
Vol 560-561 ◽  
pp. 846-852 ◽  
Author(s):  
Qi Ma ◽  
Lin Hua ◽  
Dong Sheng Qian
Keyword(s):  
Rolling Process ◽  
Small Hole ◽  
Fe Model ◽  
Forming Process ◽  
Software Environment ◽  
Cross Rolling ◽  
Design And Optimization ◽  
Forming Technology ◽  
Deep Groove ◽  
Plastic Forming

Ring parts with small-hole and deep groove such as duplicate gear and double-side flange, are widely used in various engineering machineries. Three-roll cross rolling (TRCR) is a new advanced plastic forming technology for the processing of rings with small-hole and deep groove. In this paper, a 3D coupled thermo-mechanical FE model for TRCR of ring with small-hole and deep groove is established under ABAQUS software environment. By simulation and analysis, the evolution and distribution laws of strain and temperature in the forming process are revealed, and the effects of the key process parameters on the deformation uniformity are explored. The results provide valuable guideline for the technological parameter design and optimization.

scholarly journals Does vaporized hydrogen peroxide sterilization affect the geometrical properties of anatomic models and guides 3D printed from computed tomography images?

2021 ◽  
Vol 7 (1) ◽  
Author(s):  
Mauricio Toro ◽  
Aura Cardona ◽  
Daniel Restrepo ◽  
Laura Buitrago
Keyword(s):  
Computed Tomography ◽  
Hydrogen Peroxide ◽  
Dimensional Stability ◽  
Acrylonitrile Butadiene Styrene ◽  
Dimensional Error ◽  
Material Extrusion ◽  
Anatomic Models ◽  
3D Printed ◽  
Mean Differences ◽  
Butadiene Styrene

Abstract Background Material extrusion is used to 3D print anatomic models and guides. Sterilization is required if a 3D printed part touches the patient during an intervention. Vaporized Hydrogen Peroxide (VHP) is one method of sterilization. There are four factors to consider when sterilizing an anatomic model or guide: sterility, biocompatibility, mechanical properties, and geometric fidelity. This project focuses on geometric fidelity for material extrusion of one polymer acrylonitrile butadiene styrene (ABS) using VHP. Methods De-identified computed tomography (CT) image data from 16 patients was segmented using Mimics Innovation Suite (Materialise NV, Leuven, Belgium). Eight patients had maxillary and mandibular defects depicted with the anatomic models, and eight had mandibular defects for the anatomic guides. Anatomic models and guides designed from the surfaces of CT scan reconstruction and segementation were 3D printed in medical-grade acrylonitrile butadiene styrene (ABS) material extrusion. The 16 parts underwent low-temperature sterilization with VHP. The dimensional error was estimated after sterilization by comparing scanned images of the 3D printed parts. Results The average of the estimated mean differences between the printed pieces before and after sterilization were − 0,011 ± 0,252 mm (95%CI − 0,011; − 0,010) for the models and 0,003 ± 0,057 mm (95%CI 0,002; 0,003) for the guides. Regarding the dimensional error of the sterilized parts compared to the original design, the estimated mean differences were − 0,082 ± 0,626 mm (95%CI − 0,083; − 0,081) for the models and 0,126 ± 0,205 mm (95%CI 0,126, 0,127) for the guides. Conclusion This project tested and verified dimensional stability, one of the four prerequisites for introducing vaporized hydrogen peroxide into 3D printing of anatomic models and guides; the 3D printed parts maintained dimensional stability after sterilization.

scholarly journals Development of 3D Printed Symbrachydactyly Prosthetic Hand

2019 ◽  
Vol 9 (1) ◽  
pp. 5943-5947
Keyword(s):  
3D Printing ◽  
Minimum Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Design Stage ◽  
Patient Specific ◽  
Prosthetic Hand ◽  
Simple Task ◽  
3D Printed ◽  
Electrical Component ◽  
Hand Geometry

Symbrachydactyly is a genetical problem occurred to newborn where the newborn experienced underdeveloped or shorten fingers. This condition will limit their normal as even a simple task of holding an item or pushing a button. A device is needed to help them gain a better life. The aim of this project is to fabricate a customized prosthesis hand using 3D printing technology at minimum cost. The proposed prosthetic was not embedded with any electrical component. The patient can only use the wrist to control the prosthetic part which is the prosthetic fingers. The prosthetic hand was also being developed with the patient specific features, which the initial design stage was adapted from a person’s hand geometry using a 3D scanner. Next the model of the prosthesis was analyzed computationally to predict the performance of the product. Different material properties are considered in the analysis to present Polylactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS) materials. Then, the prosthesis was fabricated using the 3D printing. The results suggested that PLA material indicated better findings and further be fabricated.

scholarly journals Design of Self-Supported 3D Printed Parts for Fused Deposition Modeling

2016 ◽  
Author(s):  
Fabian Lischke ◽  
Andres Tovar
Keyword(s):  
Numerical Model ◽  
Fused Deposition Modeling ◽  
Beam Theory ◽  
Critical Factor ◽  
Acrylonitrile Butadiene Styrene ◽  
Material Model ◽  
Analytical Models ◽  
Element Analysis ◽  
Fused Deposition ◽  
3D Printed

One of the primary challenges faced in Additive Manufacturing (AM) is reducing the overall cost and printing time. A critical factor in cost and time reduction is post-processing of 3D printed (3DP) parts, of which removing support structures is one of the most time consuming steps. Support is needed to prevent the collapse of the part or certain areas under its own weight during the 3D printing process. Currently, the design of self-supported 3DP parts follows a set of empirical guide lines. A trial and error process is needed to produce high quality parts by Fused Depositing Modeling (FDM). The usage of chamfer angle with a max 45° angle form the horizontal for FDM is a common example. Inclined surfaces with a smaller angle are prone to defects, however no theoretical basis has been fully defined, therefore a numerical model is needed. The model can predict the problematic areas at a print, reducing the experimental prints and providing a higher number of usable parts. Physical-based models have not been established due to the generally unknown properties of the material during the AM process. With simulations it is possible to simulate the part at different temperatures with a variety of other parameters that have influence on the behavior of the model. In this research, analytic calculations and physical tests are carried out to determine the material properties of the thermoplastic polymer Acrylonitrile - Butadiene - Styrene (ABS) f or FDM at the time of extrusion. This means that the ABS is going to be extruded at 200°C to 245°C and is a viscous material during part construction. Using the results from the physical and analytical models, i.e., Timoshenko’s modified beam theory for micro-structures, a numerical material model is established to simulate the filament deformation once it is deposited onto the part. Experiments were also used to find the threshold for different geometric specifications, which could then be applied to the numerical model to improve the accuracy of the simulation. The result of the finite element analysis is compared to experiments to show the correlation between the prediction of deflection in simulation and the actual deflection measured in physical experiments. A case study was conducted using an application that optimizes topology of complex geometries. After modeling and simulating the optimized part, areas of defect and errors were determined in the simulation, then verified and and measured with actual 3D prints.

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