scholarly journals An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1649
Author(s):  
Jadwiga Pisula ◽  
Grzegorz Budzik ◽  
Paweł Turek ◽  
Mariusz Cieplak
Keyword(s):  
Additive Manufacturing ◽  
Operating Temperature ◽  
Coordinate Measuring Machine ◽  
Acrylonitrile Butadiene Styrene ◽  
Spur Gear ◽  
Gear Train ◽  
Tooth Surface ◽  
Fused Filament Fabrication ◽  
Measuring Machine ◽  
Manufacturing Techniques

This article focuses on wear tests of spur gears made with the use of additive manufacturing techniques from thermoplastic materials. The following additive manufacturing techniques were employed in this study: Melted and Extruded Modelling (FDM) and Fused Filament Fabrication (FFF). The study analysed gears made from ABS M-30 (Acrylonitrile Butadiene Styrene), ULTEM 9085 (PEI Polyetherimide) and PEEK (Polyetheretherketone), and the selection of these materials reflects their hierarchy in terms of economical application and strength parameters. A test rig designed by the authors was used to determine the fatigue life of polymer gears. Gear trains were tested under load in order to measure wear in polymer gears manufactured using FDM and FFF techniques. In order to understand the mechanism behind gear wear, further tests were performed on a P40 coordinate measuring machine (CMM) and a TalyScan 150 scanning instrument. The results of the gear tests made under load allow us to conclude that PEEK is resistant to wear and gear train operating temperature. Its initial topography undergoes slight changes in comparison to ABS M-30 and Ultem 9085. The biggest wear was reported for gears made from Ultem 9085. The hardness of the material decreased due to the loaded gear train’s operating temperature.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Variance Quantification of Different Additive Manufacturing Processes for Acoustic Meta Materials

2021 ◽  
Vol 263 (4) ◽  
pp. 2708-2723
Author(s):  
Manuel Bopp ◽  
Arn Joerger ◽  
Matthias Behrendt ◽  
Albert Albers
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Production Process ◽  
Laser Scanning ◽  
Mode Shapes ◽  
Manufacturing Processes ◽  
3D Laser Scanning ◽  
Fused Filament Fabrication ◽  
Manufacturing Techniques ◽  
Different Levels

Many concepts for acoustic meta materials rely on additive manufacturing techniques. Depending on the production process and material of choice, different levels of precision and repeatability can be achieved. In addition, different materials have different mechanical properties, many of which are frequency dependent and cannot easily be measured directly. In this contribution the authors have designed different resonator elements, which have been manufactured utilizing Fused Filament Fabrication with ABSplus and PLA, as well as PolyJet Fabrication with VeroWhitePlus. All structures are computed in FEA to obtain the calculated Eigenfrequencies and mode shapes, with the respective literature values for each material. Furthermore, the dynamic behavior of multiple instances of each structure is measured utilizing a 3D-Laser-Scanning Vibrometer under shaker excitation, to obtain the actual Eigenfrequencies and mode shapes. The results are then analyzed in regards to variance between different print instances, and in regards to accordance between measured and calculated results. Based on previous work and this analysis the parameters of the FEA models are updated to improve the result quality.

scholarly journals Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes

2020 ◽  
Vol 12 (9) ◽  
pp. 3568 ◽  
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Athena Maniadi ◽  
Emmanuel Koudoumas ◽  
Achilles Vairis ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Behavior ◽  
Mechanical Response ◽  
Positive Impact ◽  
Research Work ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Simulation ◽  
Recycling Rate ◽  
Fused Filament Fabrication ◽  
Butadiene Styrene

Sustainability in additive manufacturing refers mainly to the recycling rate of polymers and composites used in fused filament fabrication (FFF), which nowadays are rapidly increasing in volume and value. Recycling of such materials is mostly a thermomechanical process that modifies their overall mechanical behavior. The present research work focuses on the acrylonitrile-butadiene-styrene (ABS) polymer, which is the second most popular material used in FFF-3D printing. In order to investigate the effect of the recycling courses on the mechanical response of the ABS polymer, an experimental simulation of the recycling process that isolates the thermomechanical treatment from other parameters (i.e., contamination, ageing, etc.) has been performed. To quantify the effect of repeated recycling processes on the mechanic response of the ABS polymer, a wide variety of mechanical tests were conducted on FFF-printed specimens. Regarding this, standard tensile, compression, flexion, impact and micro-hardness tests were performed per recycle repetition. The findings prove that the mechanical response of the recycled ABS polymer is generally improved over the recycling repetitions for a certain number of repetitions. An optimum overall mechanical behavior is found between the third and the fifth repetition, indicating a significant positive impact of the ABS polymer recycling, besides the environmental one.

scholarly journals Comparative study of the flexural properties of ABS, PLA and a PLA–wood composite manufactured through fused filament fabrication

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
J.A. Travieso-Rodriguez ◽  
R. Jerez-Mesa ◽  
Jordi Llumà ◽  
Giovanni Gomez-Gras ◽  
Oriol Casadesus
Keyword(s):  
Additive Manufacturing ◽  
Acrylonitrile Butadiene Styrene ◽  
Nozzle Diameter ◽  
Bending Test ◽  
Mechanical Resistance ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Layer Height ◽  
Maximum Deformation ◽  
Materials Used

Purpose The aim of this paper is to analyze the mechanical properties of acrylonitrile-butadiene-styrene (ABS) parts manufactured through fused filament fabrication and compare these results to analogous ones obtained on polylactic acid (PLA) and PLA–wood specimens to contribute for a wider understanding of the different materials used for additive manufacturing. Design/methodology/approach With that aim, an experimental based on an L27 Taguchi array was used to combine the specific parameters taken into account in the study, namely, layer height, nozzle diameter, infill density, orientation and printing velocity. All samples were subjected to a four-point bending test performed according to the ASTM D6272 standard. Findings Young’s modulus, elastic limit, maximum stress and maximum deformation of every sample were computed and subjected to an analysis of variance. Results prove that layer height and nozzle diameter are the most significant factors that affect the mechanical resistance in pieces generated through additive manufacturing and subjected to bending loads, regardless of the material. Practical implications The best results were obtained by combining a layer height of 0.1 mm and a nozzle diameter of 0.6 mm. The comparison of materials evidenced that PLA and its composite version reinforced with wood particles present more rigidity than ABS, whereas the latter can experience further deflection before break. Originality/value This study is of interest for manufacturers that want to decide which is the best material to be applied for their application, as it derives in a practical technical recommendation of the best parameters that should be selected to treat the material during the fused filament fabrication process.

Impact of Print Parameters on Pressure Drop in Turbulent Flow Through 3-D Printed Pipes

2020 ◽  
Author(s):  
Thomas G. Shepard ◽  
John Wentz ◽  
Tucker Bender ◽  
Derek Olmschenk ◽  
Alex Gutenberg
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Flow Characteristics ◽  
Internal Flow ◽  
Acrylonitrile Butadiene Styrene ◽  
Industrial Applications ◽  
Relative Pressure ◽  
Fused Filament Fabrication ◽  
Pressure Drops ◽  
Flow Through

Abstract Flow conduits made via additive manufacturing, commonly referred to as 3-D printing, are of increasing interest for a variety of industrial applications due to the ability to create unique and conformal flow paths that would not be possible with other fabrication techniques. Fused filament fabrication (FFF) is an additive manufacturing technique that is seeing new interest in the creation of internal flow channels with its ability to print high-temperature polymers and soluble supports. Printing parameter choices in the FFF printing process result in surfaces that can have significant profile differences that may significantly impact the flow characteristics within the conduits. In this study, two print parameters were experimentally studied for turbulent water flow through circular pipes created by fused filament fabrication out of acrylonitrile butadiene styrene (ABS). The print layer orientation relative to the flow was investigated for printing layers parallel, perpendicular, and at 45 degrees from the flow axis. Layer thickness were varied from 0.254 mm to 0.330 mm and all channels were created using soluble support structures. Pressure drops were measured for fully developed flow through pipes with an inside diameter of 5 mm and Reynolds numbers up to 62,000. Results are presented in terms of relative pressure drops as well as the wall surface roughness that would lead to such impacts. These flow-determined grain surface roughnesses are then compared against measurements of print surface roughness.

Modeling and Experimental Validation of Part-Level Thermal Profile in Fused Filament Fabrication

2019 ◽  
Author(s):  
Mriganka Roy ◽  
Reza Yavari ◽  
Chi Zhou ◽  
Olga Wodo ◽  
Prahalad Rao
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Feed Rate ◽  
Experimental Validation ◽  
Acrylonitrile Butadiene Styrene ◽  
Temperature Profiles ◽  
Maximum Absolute Error ◽  
Shape Distortion ◽  
Fused Filament Fabrication ◽  
Thermal Profile

Abstract Part design and process parameters directly influence the spatiotemporal distribution of temperature and associated heat transfer in parts made using additive manufacturing (AM) processes. The temporal evolution of temperature in AM parts is termed herein as thermal profile or thermal history. The thermal profile of the part, in turn, governs the formation of defects, such as porosity and shape distortion. Accordingly, the goal of this work is to understand the effect of the process parameters and the geometry on the thermal profile in AM parts. As a step towards this goal, the objectives of this work are two-fold: (1) to develop and apply a finite element-based framework that captures the transient thermal phenomena in the fused filament fabrication (FFF) additive manufacturing of acrylonitrile butadiene styrene (ABS) parts, and (2) validate the model-derived thermal profiles with experimental in-process measurements of the temperature trends obtained under different feed rate settings (viz., the translation velocity, also called scan speed or deposition speed, of the extruder on the FFF machine). In the specific context of FFF, this foray is the critical first-step towards understanding how and why the thermal profile directly affects the degree of bonding between adjacent roads (linear track of deposited material), which in turn determines the strength of the part, as well as, propensity to form defects, such as delamination. From the experimental validation perspective, we instrumented a Hyrel Hydra FFF machine with three non-contact infrared temperature sensors (thermocouples) located near the nozzle (extruder) of the machine. These sensors measure the surface temperature of a road as it is deposited. Test parts are printed under three different settings of feed rate, and subsequently, the temperature profiles acquired from the infrared thermocouples are juxtaposed against the model-derived temperature profiles. Comparison of the experimental and model-derived thermal profiles confirms a high-degree of correlation therein, with maximum absolute error less than 10%. This work thus presents one of the first efforts in validation of thermal profiles in FFF via in-process sensing. In our future work, we will focus on predicting defects, such as delamination and inter-road porosity based on the thermal profile.

Analytical and Experimental Tooth Contact Pattern of Large-Sized Spiral Bevel Gears in Cyclo-Palloid System

2009 ◽  
Author(s):  
Kazumasa Kawasaki ◽  
Isamu Tsuji
Keyword(s):  
Coordinate Measuring Machine ◽  
Tooth Surface ◽  
Contact Pattern ◽  
Tooth Contact ◽  
Spiral Bevel Gears ◽  
Form Errors ◽  
Bevel Gears ◽  
Measuring Machine ◽  
Spiral Bevel ◽  
Tooth Flank

The demand of large-sized spiral bevel gears has increased in recent years and hereafter the demand may increase more and more. The large-sized spiral bevel gears with equi-depth teeth are usually manufactured based on Klingelnberg cyclo-palloid system. In this paper, the tooth contact pattern of large-sized spiral bevel gears in this system are investigated analytically and experimentally. First, the tooth contact pattern and transmission errors of such gears are analyzed. The analysis method is based on simultaneous generations of tooth surface and simulations of meshing and contact. Next, the large-sized spiral bevel gears are manufactured and the tooth contact pattern of these gears is investigated experimentally. Moreover, the real tooth surfaces are measured using a coordinate measuring machine and the tooth flank form errors are detected using the measured coordinates. It is possible to analyze the tooth contact patterns of the spiral bevel gears with consideration of the tooth flank form errors expressing the errors as polynomial equations. Finally, the influence of alignment errors due to assembly on the tooth contact pattern is also investigated analytically and experimentally. These analyzed results were compared with experimental ones. As a result, two results showed a good agreement.

scholarly journals Uncertainty assessment for measurement and simulation in selective laser melting: a case study of an aerospace part

ACTA IMEKO ◽  
2020 ◽  
Vol 9 (4) ◽  
pp. 96
Author(s):  
Giulio D'Emilia ◽  
Antoniomaria Di Ilio ◽  
Antonella Gaspari ◽  
Emanuela Natale ◽  
Antonios G. Stamopoulos
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Manufacturing Process ◽  
Thermal Stresses ◽  
Hybrid Approach ◽  
Coordinate Measuring Machine ◽  
Thermal Treatments ◽  
Laser Melting ◽  
Measuring Machine ◽  
Simulation Results

<p class="Abstract"><span lang="EN-US">In this work, the additive manufacturing process selective laser melting is analysed with the aim of realising a complex piece for aerospace applications. In particular, the effect of the manufacturing process and of the following thermal treatments on the dimensions of the workpiece is evaluated. The study is based on a hybrid approach including a simulation of the whole manufacturing process by advanced software packages and the dimensional measurements of the realised pieces taken by a coordinate measuring machine (CMM). The integrated use of simulation and measurements is carried out with the aim of validating the simulation results and of identifying the operational limits of both approaches; this analysis is based on metrological evaluation of the results of both the simulation and the tests, taking into account the uncertainty of the data. In addition, the main causes of uncertainty for the simulation activity and the experimental data have been identified, and the effects of some of them have also been experimentally evaluated. Based on the experimental validation, the simulation seems to predict the absolute displacement of the supports of the piece in a satisfactory way, while it is unable, in the actual configuration, to assess the conformity of the surface to its very tight shape tolerances. Conformity assessment of the surface should be carried out by CMM measurement. Integrated use of simulation and experimental results is expected to strongly improve the accuracy of simulation results for the effective and accurate design and control of the additive manufacturing process, including dimensional control and thermal treatments to mitigate induced thermal stresses.</span></p>

Study on Building Digital-Twin of Face-Milled Hypoid Gear From Measured Tooth Surface Topographical Data

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Yi-Hui Lee ◽  
Zhang-Hua Fong
Keyword(s):  
Coordinate Measuring Machine ◽  
Industrial Applications ◽  
Tooth Surface ◽  
Position Vector ◽  
Normal Vector ◽  
Hypoid Gear ◽  
Principal Curvatures ◽  
Digital Twin ◽  
Design Variables ◽  
Measuring Machine

Abstract A highly accurate digital-twin spiral bevel gear or hypoid gear is often required for dynamic analysis or stress analysis for gear transmission. However, a highly accurate digital-twin solid model is not always available because the final hypoid gear is completed by the gear manufacturer. This study constructs a digital-twin from a sample hypoid gear. The tooth surface of sample gear is digitized as topographical grids using a coordinate measuring machine (CMM) or a gear measurement center. The geometric parameters (the surface position vector, the normal vector, the principal curvatures, and the corresponding principal directions) for the measured tooth surface (MTS) are then extracted using numerical differential geometry (NDG). The machine settings and the cutter parameters for the sample hypoid gear are obtained by minimizing the topographical error between the replicated digital-twin and the sample gear using optimization software. The initial estimation for the machine settings and the cutter parameters is calculated using an explicit form of the modified-roll motion (MRM), which decreases numerical divergence and time that is required for calculation. The machine settings, the cutting tool parameters, and the auxiliary flank modification (AFM) motion are used as the design variables. A numerical example is presented to verify the proposed methodology. The numerical results show that the replicated digital-twin that is developed using the proposed method is sufficiently accurate for industrial applications.

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