scholarly journals Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Metals ◽  
2019 ◽  
Vol 9 (8) ◽  
pp. 811 ◽  
Author(s):  
Jørgen Blindheim ◽  
Torgeir Welo ◽  
Martin Steinert
Keyword(s):  
Additive Manufacturing ◽  
Material Flow ◽  
Deposition Process ◽  
Feed Speed ◽  
Element Analysis ◽  
Reduced Pressure ◽  
Metal Structures ◽  
Material Deposition ◽  
Flow Through ◽  
Metal Extrusion

Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered metal structures. This new deposition process is a complex metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.

Parallel Extrusion of Aluminum Alloy Heat Sink with Round-Fin

2013 ◽  
Vol 739 ◽  
pp. 131-135
Author(s):  
Li Han Zhang ◽  
Ke Sheng Wang ◽  
Yu Han ◽  
Jia Yu Ying
Keyword(s):  
Heat Sink ◽  
Material Flow ◽  
Extrusion Process ◽  
Element Analysis ◽  
Automotive Lighting ◽  
Metal Sheets ◽  
The Finite Element Analysis ◽  
Alloy Heat ◽  
Flow Through ◽  
Good Agreement

Parallel extrusion is a combined extrusion process for forming round-fin heat sink on thick metal sheets. In this paper, the parallel extrusion has been applied to manufacture the round-fin heat sink in the automotive lighting. Numerical simulations on the round-fin heat sink forming using the software DEFORM were carried out. The tooling structure with counterpressure on the heat sink formation was investigated. The results show that the tooling structure with counterpressure is helpful to the formation of round-fin heat sink, which not only ensures the height of each round-fin on the heat sink is uniform but also retards the initiation of flow-through on the reverse side of round-fin. In addition, the experiments of press forging process were conducted to validate the finite element analysis, it is shown that the friction at the punch-blank interface has more significant effect on preventing the initiation of flow-through compared with the friction at the die-blank interface, which implies that the punch-blank interface has more significant effect on the material flow in the formation of round-fin, and the simulation results are in good agreement with the experimental data.

Towards Assembly-Free Methods for Additive Manufacturing Simulation

2015 ◽  
Author(s):  
Anirudh Krishnakumar ◽  
Krishnan Suresh ◽  
Aaditya Chandrasekar
Keyword(s):  
Additive Manufacturing ◽  
Stiffness Matrix ◽  
Deposition Process ◽  
Implementation Challenges ◽  
Advantages And Disadvantages ◽  
Material Deposition ◽  
Element Simulation ◽  
Non Linear ◽  
Global Stiffness Matrix ◽  
Linear Systems Of Equations

There is significant interest today in the finite element simulation of various Additive Manufacturing (AM) processes. AM simulation is time-dependent, inherently non-linear, and involves multiple physics. In addition, repeated meshing and insertion of new elements during material deposition can pose significant implementation challenges. Currently, AM simulation is handled either through a ‘quiet’ approach or an ‘inactive’ approach. In the quiet approach, all finite elements within the workspace are assembled into the global stiffness matrix, and the elements yet to be deposited are assigned ‘void’ material properties. In the inactive approach, only the elements that have been deposited are assembled into the global stiffness matrix. The advantages and disadvantages of the two methods are well documented. In this paper, we propose a voxel-based, assembly-free framework for AM simulation. This framework presents several advantages including. (1) The workspace is meshed only once at the start of the simulation, (2) addition and deletion of elements is trivial, (3) reduced memory requirement as the global stiffness matrix is never assembled and (4) the underlying linear systems of equations can be solved efficiently through assembly-free methods. We demonstrate the framework here by simulating transient non-linear thermal behaviour of a laser deposition process, with material deposition.

scholarly journals An Automated Open-Source Approach for Debinding Simulation in Metal Extrusion Additive Manufacturing

Designs ◽  
2021 ◽  
Vol 5 (1) ◽  
pp. 2
Author(s):  
Tobias Rosnitschek ◽  
Johannes Glamsch ◽  
Christopher Lange ◽  
Bettina Alber-Laukant ◽  
Frank Rieg
Keyword(s):  
Additive Manufacturing ◽  
Open Source ◽  
Selection Process ◽  
Product Development Process ◽  
Element Analysis ◽  
Powder Bed ◽  
Optimal Orientation ◽  
Automated Simulation ◽  
Manufacturing Applications ◽  
Metal Extrusion

As an alternative to powder-bed based processes, metal parts can be additively manufactured by extrusion based additive manufacturing. In this process, a highly filled polymer filament is deposited and subsequently debindered and sintered. Choosing a proper orientation of the part that satisfies the requirements of the debinding and sintering processes is crucial for a successful manufacturing process. To determine the optimal orientation for debinding, first, the part must be scaled in order to compensate the sinter induced shrinkage. Then, a finite element analysis is performed to verify that the maximum stresses due to the dead load do not exceed the critical stress limits. To ease this selection process, an approach based on open source software is shown in this article to efficiently determine a part’s optimal orientation during debinding. This automates scaling, debinding simulation, and postprocessing for all six main directions. The presented automated simulation framework is examined on three application examples and provides plausible results in a technical context for all example parts, leading to more robust part designs and a reduction of experimental trial and error. Therefore, the presented framework is a useful tool in the product development process for metal extrusion additive manufacturing applications.

Development of a high-speed laser material deposition process for additive manufacturing

2021 ◽  
Vol 33 (1) ◽  
pp. 012021
Author(s):  
Jonathan Schaible ◽  
Lennart Sayk ◽  
Thomas Schopphoven ◽  
Johannes Henrich Schleifenbaum ◽  
Constantin Häfner
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Deposition Process ◽  
Laser Material ◽  
Material Deposition

A Network Based Modelling Approach Using the Dimensional Analysis Conceptual Modeling (DACM) Framework for Additive Manufacturing Technologies

2016 ◽  
Author(s):  
Hossein Mokhtarian ◽  
Eric Coatanéa ◽  
Henri Paris ◽  
Tuomas Ritola ◽  
Asko Ellman ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Analysis ◽  
System Architecture ◽  
Conceptual Modeling ◽  
Deposition Process ◽  
Illustrative Case ◽  
Influence Of Process Parameters ◽  
Modelling Framework ◽  
Material Deposition ◽  
Manufacturing Technologies

The application of additive manufacturing technologies in the industry is growing fast. This leads to an increasing need for reliable modeling techniques in the field of additive manufacturing. A methodology is proposed to systematically assess the influence of process parameters on the final characteristics of additively manufactured parts. The current study aims at presenting a theoretical framework dedicated to the modeling of the additive manufacturing technology. More specifically, the framework is used in the context of the study to plan and optimize the experimental process to minimize the amount of experiments required to populate the model. The framework presented is based on the Dimensional Analysis Conceptual Modelling framework (DACM). DACM is an approach supporting the production of models. This approach is designing networks representing a system architecture and behavior using an approach sharing similarities with neural networks. Based on the proposed approach, it is possible to detect where supplementary experimental data have to be collected to complete the model generated by the DACM approach. The modeling of the Direct Material Deposition process is conducted as an illustrative case study. The scope of the approach is vast and supported by validated scientific methods combined to form the core of the DACM method. The DACM framework is step by step extracting information from a description of the system architecture to create semi-automatically a model that can be simulated and used for multiple types of analyses associated for example with innovation and design improvement. The current paper will focus on the usage of the DACM framework, recently developed in a project, in the field of additive manufacturing.

Additive Manufacturing of Multi-Material and Composite Parts

2020 ◽  
pp. 127-146
Author(s):  
V. Senthilkumar ◽  
Velmurugan C. ◽  
K. R. Balasubramanian ◽  
M. Kumaran
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Functionally Graded Materials ◽  
Deposition Process ◽  
Functionally Graded ◽  
Subsequent Stage ◽  
Functional Requirements ◽  
Graded Materials ◽  
Material Deposition ◽  
Single Part

Additive manufacturing (AM) technology can be employed to produce multimaterial parts. In this approach, multiple types of materials are used for the fabrication of a single part. Custom-built functionally graded, heterogeneous, or porous structures and composite materials can be fabricated thorough this process. In this method, metals, plastics, and ceramics have been used with suitable AM methods to obtain multi-material products depending on functional requirements. The process of making composite materials by AM can either be performed during the material deposition process or by a hybrid process in which the combination of different materials can be performed before or after AM as a previous or subsequent stage of production of a component. Composite processes can be employed to produce functionally graded materials (FGM).

scholarly journals Additive Manufacturing of Ti6Al4V with Wire Laser Metal Deposition Process

2021 ◽  
Vol 1016 ◽  
pp. 24-29
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Deposition Process ◽  
Travel Speed ◽  
Beam Power ◽  
Feed Speed ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Growth Prospects ◽  
Wire Feed

Additive manufacturing (AM) using wire as an input material is currently in full swing, with very strong growth prospects thanks to the possibility of creating large parts, with high deposition rates, but also a low investment cost compared to the powder bed fusion machines. A versatile 3D printing device using a Direct Energy Deposition Wire-Laser (DED-W Laser) with Precitec Coaxprinter station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters. The geometrical and metallurgical of produced parts are analyzed. In the literature, several authors agree to define wire feed speed, travel speed, and laser beam power as first-order process parameters governing laser-wire deposition. This study shows the relative importance of these parameters taking separately as well as the importance of their sequencing at the start of the process. Titanium deposit are obtained with powers never explored in bibliography (up to 5 kW), and wire feed speed up to 5 m.min-1 with a complete process repeatability.

scholarly journals Modeling and Experimental Study of the Localized Electrochemical Micro Additive Manufacturing Technology Based on the FluidFM

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2783
Author(s):  
Wanfei Ren ◽  
Jinkai Xu ◽  
Zhongxu Lian ◽  
Peng Yu ◽  
Huadong Yu
Keyword(s):  
Additive Manufacturing ◽  
Complex Structure ◽  
Three Dimensional ◽  
Linear Structure ◽  
Deposition Process ◽  
Manufacturing Technology ◽  
Large Area ◽  
Metal Structures ◽  
Additive Manufacturing Technology ◽  
Liquid Feeding

In this work, the localized electrochemical micro additive manufacturing technology based on the FluidFM (fluidic force microscope) has been introduced to fabricate micro three-dimensional overhang metal structures at sub-micron resolution. It breaks through the localized deposition previously achieved by micro-anode precision movement, and the micro-injection of the electrolyte is achieved in a stable electric field distribution. The structure of electrochemical facilities has been designed and optimized. More importantly, the local electrochemical deposition process has been analyzed with positive source diffusion, and the mathematical modeling has been revealed in the particle conversion process. A mathematical model is proposed for the species flux under the action of pulsed pressure in an innovatively localized liquid feeding process. Besides, the linear structure, bulk structure, complex structure, and large-area structure of the additive manufacturing are analyzed separately. The experimental diameter of the deposited cylinder structure is linearly fitted. The aspect ratio of the structure is greater than 20, the surface roughness value is between 0.1–0.2 μm at the surface of bulk structures, and the abilities are verified for deposition of overhang, hollow complex structures. Moreover, this work verifies the feasibility of 3D overhang array submicron structure additive manufacturing, with the application of pulsed pressure. Furthermore, this technology opens new avenues for the direct fabrication of nano circuit interconnection, tiny sensors, and micro antennas.

scholarly journals Determination of the region of the limiting states occurrence in RVS-20000 with the subsidence of the external bottom contour

2018 ◽  
Vol 239 ◽  
pp. 06002
Author(s):  
P.V. Chepur ◽  
A.A. Tarasenko ◽  
A.A. Gruchenkova
Keyword(s):  
Technical Condition ◽  
Element Analysis ◽  
Metal Structures ◽  
Software Complex ◽  
Managerial Decisions ◽  
The Finite Element Analysis ◽  
Steel Tank ◽  
Intrinsic Stiffness ◽  
Bottom Contour

The problem of the limiting states occurrence in the structures of a vertical steel tank is investigated in this work. To study the SSS of the metal structures of the object, the authors created a numerical model of the RVS-20000 tank in the ANSYS software complex. The model considers the maximum number of elements with their geometry and connections affecting the tank SSS under non-axisymmetric loading, including beyond the elasticity of steel. Dependences between the parameters of intrinsic stiffness of the VST are obtained. The results of the finite element analysis made it possible to develop a technique for assessing the technical condition of the structure with the development of irregular subsidence of the external bottom contour. The proposed technique can be used by both operating and design organizations in making managerial decisions regarding the repair of RVS-20000 subjected to the base subsidence.

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