Download or read book A Process Modelling and Parameters Optimization and Recommendation System for Binder Jetting Additive Manufacturing Process written by Han Chen and published by . This book was released on 2016 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "Binder Jetting (BJ) process is an Additive Manufacturing (AM) process in which powder materials are selectively joined by binder materials. Products can be manufactured layer by layer directly from 3D model data. It is not always easy for manufacturing engineers to choose proper BJ process parameters to meet the end-product quality and fabrication time requirements. This is because the quality properties of the products fabricated by the BJ process are significantly affected by the process parameters. The relationships between process parameters and quality properties are also very complicated. It is because the BJ AM process involves many different disciplines and physics theories, such as 3D computer graphics, Computer Numerical Control (CNC), metallurgy theory, materials science and chemistry, etc. In this research, a process model is developed by the Backward Propagation (BP) Neural Network (NN) algorithm based on 16 groups of orthogonal experiments designed by the Taguchi Method to express the relationships between 4 key process parameters and 2 key quality properties. The results are also converted to Signal-to-Noise (S/N) ratios and analyzed by the Analysis of Variance (ANOVA). An intelligent parameters recommendation system is developed to predict end-product quality properties and printing time with a given design. It can recommend process parameters based on the quality requirements. Some physical interpretations are introduced to explain the experiment results. 4 different sets of optimal parameters are concluded. They are verified by 4 groups of confirmation tests as well. A case study of an aircraft engine bracket is also conducted to verify the proposed system. The research outcome can be used as a guideline for selecting the proper printing parameters to achieve the desired properties and help to improve the quality control of components fabricated by the BJ AM process." --

Download or read book Process Parameter Optimization with Numerical Modelling and Experimentation Design of Binder Jet Additive Manufacturing written by Sairam Vangapally and published by . This book was released on 2017 with total page 88 pages. Available in PDF, EPUB and Kindle. Book excerpt: Binder jetting technology is an additive manufacturing technology in which powder materials are binded together layer by layer forming the product from input CAD model. The process involves printing the product layer by layer, curing and sintering. The mechanical properties of 3D printed samples varies based on process parameters, hence there is a need to tune the process parameters for optimal characteristics. Three main parameters namely layer thickness, sintering time and sintering temperature were identified and the study focuses on the effect of parameters on dimensional accuracy and compressive strength of the samples. Full factorial experimental approach was used to conduct the experiments and analysis of variance was performed to determine the significance of parameters. Along with parameters optimization, feed forward back propagation artificial neural network model is developed to quantify the relationship between three parameters and compressive strength, the model is developed based on experimental data and validated with known data. Also, Compressive behavior of four lattice designs considered in the study were simulated by finite element analysis and numerical results were compared with experimental data in order to validate the finite element model. FE models of different lattice designs were developed from experimental test data using ANSYS and the simulated compressive behavior is compared to that experimental compression test results.

Download or read book Innovative Product Development by Additive Manufacturing 2022 written by Roland Lachmayer and published by Springer Nature. This book was released on 2023-03-07 with total page 158 pages. Available in PDF, EPUB and Kindle. Book excerpt: The book consists of a collection of papers from a corresponding conference regarding additive manufacturing. The yearly conference used to be held in German under the title "Konstruktion für die Additive Fertigung" and is held in English since last year. The topics are Specifications, potentials, and solutions Contributions to specifications on components and processes and methods for assessing the suitability of components and the application of additive manufacturing and finding solutions for concepts and design Design and optimization Contributions to the development and design of components, their design to ensure functional requirements and manufacturability, and methods and tools for optimization components Simulation, validation, and quality assurance Contributions to approaches for the computer-aided and physical validation of components, the testing of components and material, and measures to ensure quality aspects Process chain and business models Contributions to their integration of additive manufacturing processes into existing processes and measures to increase value creation and the creation of new business models.

Download or read book Additive Manufacturing Technology written by Kun Zhou and published by John Wiley & Sons. This book was released on 2023-02-28 with total page 405 pages. Available in PDF, EPUB and Kindle. Book excerpt: Highly comprehensive resource covering all key aspects of the current developments of additive manufacturing Additive Manufacturing Technology: Design, Optimization, and Modeling provides comprehensive and in-depth knowledge of the latest advances in various additive manufacturing technologies for polymeric materials, metals, multi-materials, functionally graded materials, and cell-laden bio-inks. It also details the application of numerical modeling in facilitating the design and optimization of materials, processes, and printed parts in additive manufacturing. The topics covered in this book include: Fundamentals and applications of 4D printing, 3D bioprinting of cell-laden bio-inks, and multi-material additive manufacturing Alloy design for metal additive manufacturing, mechanisms of metallurgical defect formation, and the mechanical properties of printed alloys Modified inherent strain method for the rapid prediction of residual stress and distortion within parts fabricated by additive manufacturing Modeling of the different stages in polymer and metal additive manufacturing processes, including powder spreading, melting, and thermal stress evolution By providing extensive coverage of highly relevant concepts and important topics in the field of additive manufacturing, this book highlights its essential role in Industry 4.0 and serves as a valuable resource for scientists, engineers, and students in materials science, engineering, and biomedicine.

Download or read book Advances in Pre and Post Additive Manufacturing Processes written by Naveen Mani Tripathi and published by CRC Press. This book was released on 2024-06-18 with total page 255 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book provides knowledge about the process of creating and designing products based on an Industry 4.0 setting. The fundamentals of Additive Manufacturing, its many technologies, the process parameters, advantages, limitations, and recent developments are discussed. In addition, the most recent post-additive manufacturing process advancements, surface quality defects, and challenges are the primary topics that will be investigated in the book. Advances in Pre- and Post-Additive Manufacturing Processes: Innovations and Applications provides scientific and technological insights into the physical fundamentals of the machining and finishing processes in macro, micro, and nanoscales. It explores in a systematic way both conventional and unconventional material-shaping processes with various modes of hybridization concerning theory modelling and industrial potential. It focuses on the applications of Additive Manufacturing that are linked to pre-stage and post-stage processes and encompasses a broad spectrum of macro, micro, and nano-processes that are utilized in manufacturing activities. The book goes on to cover a wide range of reliable and economical fabrication of metallic parts with complicated geometries which are of considerable interest to the aerospace, medical, automotive, tooling, and consumer products industries. This reference title encapsulates the current trends of today’s material development and machining techniques for advanced composite materials, making it a one-stop resource for academic researchers and industrial firms while they are formulating strategic development strategies. It also serves as a reference book for students at all levels of education, from undergraduates to doctoral candidates.

Download or read book Springer Handbook of Additive Manufacturing written by Eujin Pei and published by Springer Nature. This book was released on 2023-11-25 with total page 994 pages. Available in PDF, EPUB and Kindle. Book excerpt: This Handbook is the ultimate definitive guide that covers key fundamentals and advanced applications for Additive Manufacturing. The Handbook has been structured into seven sections, comprising of a thorough Introduction to Additive Manufacturing; Design and Data; Processes; Materials; Post-processing, Testing and Inspection; Education and Training; and Applications and Case Study Examples. The general principles and functional relationships are described in each chapter and supplemented with industry use cases. The aim of this book is to help designers, engineers and manufacturers understand the state-of-the-art developments in the field of Additive Manufacturing. Although this book is primarily aimed at students and educators, it will appeal to researchers and industrial professionals working with technology users, machine or component manufacturers to help them make better decisions in the implementation of Additive Manufacturing and its applications.

Download or read book Productivity Evaluation Model of Binder jetting Additive Manufacturing Processes written by Yuhaowei Zhou and published by . This book was released on 2015 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "The interests towards Additive Manufacturing (AM) technologies are rapidly rising due to their great potential in new product design possibilities and the reduction of environmental impacts. Currently AM technologies are largely investigated in automotive, aerospace and medical equipment industries on design, production quality and manufacturability aspects. Due to its inherited layer by layer fabrication process, there is a concern regarding to the manufacturing efficiency of AM processes. However, there is very limited research on productivity of AM, which includes the time consumption, raw material consumption and the production efficiency. This paper presents a simulation method to assess the productivity of AM. Based on this method, a productivity model of Binder-Jetting AM technology is created. Binder-Jetting AM (BJAM) is one of the commercialized AM technologies which can process a variety of materials including stainless steel, ceramic, sand and polymer. Process decomposition is performed to analyze the BJAM printing process. Curing and sintering process as well as manual processing procedure are also included as part of a complete production system of BJAM. Life Cycle Assessment (LCA) model is developed in order to evaluate the whole production process and the production-consumption relation. Experiments are conducted in order to collect data on operation and manipulation time of the machine and actual material consumption. Based on experimental data, an evaluation algorithm has been developed in estimating the time and material consumption as a function of part geometry and process parameters. Several process parameters are taken into account, including the layer thickness, spreading speed, drying time, binder saturation, drying power and curing and sintering profiles. Furthermore, the production efficiency is assessed on adapted Key Performance Indicator (KPI). Machine Availability, Machine Efficiency, Material Efficiency, Material Consumption Ratio, Waste Ratio and Machine Preparation degree are considered. An estimation of the production time, material consumption as well as the KPIs from the given STL design file and the recommended process parameters is given as the output of the productivity model. Finally, A Case study is performed to validate the BJAM algorithms and productivity model. The result shows that the Productivity Model can provide reliable estimation of the time and material consumption of the BJAM production system." --

Download or read book Recent Advances in Materials Processing and Characterization written by A. Arockiarajan and published by Springer Nature. This book was released on 2022-09-29 with total page 380 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents select proceedings of the International Conference on Materials Processing and Characterization (ICMPC 2021). It particularly focuses on emerging trends related to advanced materials processing and characterization and current practices in industries. It discusses innovative manufacturing processes, standards and technologies used to broaden the knowledge of materials and also help to increase innovation and responsiveness to ever-increasing international needs, more in-depth studies of functionally graded materials/ tailor-made materials. This book will be a valuable resource for students, researchers, and professionals working in the various areas of materials science.

Download or read book Advances in Additive Manufacturing Materials Processes and Applications written by Tarek Mabrouki and published by Springer Nature. This book was released on 2023-11-03 with total page 257 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book reports on research and developments in the field of 3D printing, with a special emphasis on methods to analyse the products of additive manufacturing, and optimize different steps of the manufacturing process. Gathering selected contributions to the 2nd Advances in Additive Manufacturing Conference (AIAM' 2023), held on Mai 18-20, 2023, in Hammamet, Tunisia, this book covers a variety of topics, including: analysis of microstructure and material behavior, numerical simulation and model techniques for optimization of manufacturing processes, machine learning for quality control and automated monitoring, among others. Offering a good balance of fundamental research and industrially relevant findings, this book provides researchers and professionals with a timely snapshot of and extensive information on current developments in the field and a source of inspiration for future research and collaboration.

Download or read book Development of Computer aided Design Evaluation CADE System for Binder Jetting Additive Manufacturing Process from a Manufacturability Perspective written by Fan Yang and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "Due to the additive way of manufacturing parts layer by layer, additive manufacturing (AM) is subjected to fewer design constraints than traditional manufacturing techniques. The intricate and complex structures that cannot be fabricated by traditional methods can be realized by AM. However, it should be noted that the manufacturing capability of AM is not limitless. The unprecedented design freedom of AM can only be fully utilized when the unique manufacturability of AM is well investigated and the design methodology specially for AM, also known as design for AM (DFAM), is developed.One popular topic of the DFAM research is to propose feature-based design guidelines based on experimental investigations. These simple-to-follow rules normally oversimplify the dependent relation between the manufacturability of features and their corresponding manufacturability parameters. To compensate for this shortcoming in the design guidelines, manufacturability analysis is needed to examine designs before manufacturing takes place. In this thesis, a computer-aided design evaluation (CADE) system is proposed to perform manufacturability analysis on computer-aided design (CAD) models for the specific AM process. The CADE system consists of three consecutive modules: feature detection, feature evaluation and orientation optimization. Logical rule-based method, artificial neural network (ANN) and genetic algorithm (GA) are used to develop the three modules, respectively. A design of experiments (DoE) method is proposed to study the AM manufacturability with respect to selected aspects of geometric dimensioning and tolerancing (GD&T) in a comprehensive yet economical way. The proposed framework is implemented for the binder jetting additive manufacturing (BJAM) process. Based on the proposed DoE method, the manufacturability of overhang structures and through holes are investigated experimentally with respect to angularity and cylindricity respectively. The knowledge and experimental data gained in the extensive experimental work are then used to develop the CADE system. With the support of the developed CADE system, designers can examine critical features in their designs from the manufacturability perspective for the specific BJAM process. In this way, the features that are prone to failing are identified in advance so that designers could modify them to decrease the risk of manufacturing failures." --

Download or read book Novel Efficient Global Optimization and Simulation Methods Applied to Additive Manufacturing Process Design written by Long Wang (Ph. D. in aerospace engnieering) and published by . This book was released on 2021 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) or three-dimensional (3D) printing has become one of the most promising commercial manufacturing techniques. Benefits of AM include delivery savings as parts are made on-site, lower environmental wastes with less warehousing, and (in some cases) improved product quality and performance. The current knowledge and technology for metal AM thermal, stress, and strain prediction is mainly driven by numerical methods such as FEM, which limit the calculation of the stress and strain in a mesh-dependent setting and limit the computational efficiency of the analysis. We employ a Discrete Source Model (DSM), which estimates the thermal field independent of mesh. The effect of heat source parameters on the predicted melting pool geometry has been studied using a double-elliptical version of DSM. The parameters of our DSM model are validated with experimental data and compared the model with a model proposed previously known as “the point source model” for melt pool geometry estimations. Then, we propose a mesh-independent thermal and residual stress estimation method for the metal additive manufacturing process. We also compare McDowell and radial return method for updating plastic stress rate for the residual stress estimation process. The above method enables fast in-process estimation of stress and strain of the part. Methods based on Gaussian Stochastic Process (GSP) models and Expected Improvement (EI) functions have been promising for box-constrained expensive optimization problems. These include robust d4esign problems with environmental variables having set-type constraints. However, the methods that combine GSP and EI sub-optimizations suffer from the following problem, limiting their computational performance. Efficient Global Optimization (EGO) methods often repeat the same or nearly the same experimental points. We present a novel EGO-type constraint-handling method that maintains a so-called “tabu list” to avoid past points. Our method includes two types of penalties for the key “infill” optimization, which selects the subsequent test runs. We benchmark our Tabu EGO algorithm with five alternative approaches, including DIRECT methods using nine test problems and two engineering examples. We consider both deterministic and “noisy” simulation optimization problems. The engineering examples are based on additive manufacturing process parameter optimization using point-based thermal simulations and robust-type quality constraints. Our test problems span unconstrained, simply constrained, and robust constrained problems. The comparative results imply that Tabu EGO offers promising computational performance for all types of black-box optimization in terms of convergence speed and the quality of the final solutions.

Download or read book Modern Materials and Manufacturing Techniques written by Ravi Kant and published by CRC Press. This book was released on 2024-03-05 with total page 334 pages. Available in PDF, EPUB and Kindle. Book excerpt: The text provides the reader with an in-depth understanding of the need for next-generation materials and manufacturing, especially in terms of their designing process, manufacturing, upscaling, and finally their selection for industrial applications. It further discusses path-planning strategies for robot-based additive manufacturing. Discusses synthesis, modelling, and analysis of green composites and functionally graded materials. Explains hybrid manufacturing processes to address the challenges faced by the manufacturing industries. Covers additive manufacturing of advanced materials for smart products. Presents applications of lasers for sensing, characterization, and material processing. Illustrates principles and applications of 4D printing and cold spray-based additive manufacturing. The book focuses on sustainability in material and manufacturing processes. It covers important topics such as material recycling, optimal utilization of resources, green materials, improving surface inhomogeneity, stable material properties, and utilization of renewable energy sources. The text highlights the applications of deep learning for diagnosis and analysis in materials and manufacturing technologies. It is primarily written for senior undergraduate, graduate students, and academic researchers in the fields of manufacturing engineering, industrial and production engineering, materials science and engineering, and mechanical engineering.

Download or read book Machine Learning for Powder Based Metal Additive Manufacturing written by Gurminder Singh and published by Elsevier. This book was released on 2024-09-04 with total page 291 pages. Available in PDF, EPUB and Kindle. Book excerpt: Machine Learning for Powder-based Metal Additive Manufacturing outlines machine learning (ML) methods for additive manufacturing (AM) of metals that will improve product quality, optimize manufacturing processes, and reduce costs. The book combines ML and AM methods to develop intelligent models that train AM techniques in pre-processing, process optimization, and post-processing for optimized microstructure, tensile and fatigue properties, and biocompatibility for various applications. The book covers ML for design in AM, ML for materials development and intelligent monitoring in metal AM, both geometrical deviation and physics informed machine learning modeling, as well as data-driven cost estimation by ML. In addition, optimization for slicing and orientation, ML to create models of materials for AM processes, ML prediction for better mechanical and microstructure prediction, and feature extraction by sensing data are all covered, and each chapter includes a case study. - Covers machine learning (ML) methods for additive manufacturing (AM) of metals that will improve product quality, optimize manufacturing processes, and reduce costs - Combines ML and AM methods to develop intelligent models that train AM techniques in pre-processing, process optimization, and post-processing for optimized microstructure, tensile and fatigue properties, and biocompatibility for various applications - Discusses algorithm development of ML for metal AM, metal AM process modeling and optimization, mathematical and simulation studies of metal AM, and pre- and post-processing smart methods for metal AM

Download or read book Modeling and Optimization of Powder Based Additive Manufacturing AM Processes written by Ratnadeep Paul and published by . This book was released on 2013 with total page 204 pages. Available in PDF, EPUB and Kindle. Book excerpt: Metal powder based additive manufacturing (AM) processes are increasingly being accepted across several industries such as aerospace, automobile, medical, consumer products and electronics systems. However, the most pressing issues faced by AM technology today are concerns in achieving part accuracy and excessive material and energy utilization. Therefore, a comprehensive part-level approach analyzing the relation between the different physical phenomena occurring during the manufacturing of a metal AM part is required. A comprehensive virtual manufacturing model has been developed for simulating the surface of parts manufactured using metal powder based AM processes. The virtual manufacturing model simulates the geometry of the AM part using computational geometry techniques. Points are sampled from the surface of the simulated parts simulated and used for calculating the Geometric Dimensioning and Tolerancing (GD & T) errors and also for correlating these errors to the input parameters. The geometric virtual manufacturing model is further augmented by material shrinkage and thermal deformation error models. The shrinkage model estimates the effect of material shrinkage in AM part errors while the thermal deformation model analyzes the combined effect of shrinkage and thermal deformation on part errors. The Stereolithography (STL) file format approximates part surfaces with planar triangular facets resulting in errors in the manufactured part. Another file format, called Additive Manufacturing File (AMF) format uses recursive sub-division of curved triangles into planar triangles which however, leads to the same approximation error. This research introduces a new format which uses curved Steiner patches for approximating part surfaces and generating the different slices. Several test surfaces and parts are virtually manufactured using the Steiner format and the GD & T errors of the manufactured parts are calculated and compared with those parts manufactured using the STL and AMF representations. Support structures are additional material sintered during the manufacturing of an AM part for supporting internal cavities and overhangs. This study presents a voxel based algorithm for calculating the location and the volume of support structures used in AM processes and correlating them to the process parameters. Two parametric energy models have also been developed in this research: one for calculating the total process energy in AM processes which do not use supports and another for those processes which require supports for overhangs and holes. The first energy model uses a convex hull approach while the second model applies the voxel algorithm to develop a predictive model for calculating the total energy expended in AM processes. Finally, optimization models have been developed which minimize part errors, part strength, material utilization and energy expenditure in metal powder AM process by varying the process parameters and calculating their optimal values. The optimization algorithms will assist AM practitioners in producing error free parts the first time ("first part right"), thereby eliminating the trial and error process currently associated with manufacturing an AM part. They will also reduce the material utilization and the energy footprint of powder based AM processes, thereby driving down the costs associated with producing parts by metal powder based AM processes.

Download or read book 3D Printing and Additive Manufacturing Technologies written by L. Jyothish Kumar and published by Springer. This book was released on 2018-06-07 with total page 308 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book presents a selection of papers on advanced technologies for 3D printing and additive manufacturing, and demonstrates how these technologies have changed the face of direct, digital technologies for the rapid production of models, prototypes and patterns. Because of their wide range of applications, 3D printing and additive manufacturing technologies have sparked a powerful new industrial revolution in the field of manufacturing. The evolution of 3D printing and additive manufacturing technologies has changed design, engineering and manufacturing processes across such diverse industries as consumer products, aerospace, medical devices and automotive engineering. This book will help designers, R&D personnel, and practicing engineers grasp the latest developments in the field of 3D Printing and Additive Manufacturing.

Download or read book Metal Additive Manufacturing written by Dyuti Sarker and published by John Wiley & Sons. This book was released on 2021-10-26 with total page 624 pages. Available in PDF, EPUB and Kindle. Book excerpt: METAL ADDITIVE MANUFACTURING A comprehensive review of additive manufacturing processes for metallic structures Additive Manufacturing (AM)—also commonly referred to as 3D printing—builds three-dimensional objects by adding materials layer by layer. Recent years have seen unprecedented investment in additive manufacturing research and development by governments and corporations worldwide. This technology has the potential to replace many conventional manufacturing processes, enable the development of new industry practices, and transform the entire manufacturing enterprise. Metal Additive Manufacturing provides an up-to-date review of all essential physics of metal additive manufacturing techniques with emphasis on both laser-based and non-laser-based additive manufacturing processes. This comprehensive volume covers fundamental processes and equipment, governing physics and modelling, design and topology optimization, and more. The text adresses introductory, intermediate, and advanced topics ranging from basic additive manufacturing process classification to practical and material design aspects of additive manufacturability. Written by a panel of expert authors in the field, this authoritative resource: Provides a thorough analysis of AM processes and their theoretical foundations Explains the classification, advantages, and applications of AM processes Describes the equipment required for different AM processes for metallic structures, including laser technologies, positioning devices, feeder and spreader mechanisms, and CAD software Discusses the opportunities, challenges, and current and emerging trends within the field Covers practical considerations, including design for AM, safety, quality assurance, automation, and real-time control of AM processes Includes illustrative cases studies and numerous figures and tables Featuring material drawn from the lead author’s research and professional experience on laser additive manufacturing, Metal Additive Manufacturing is an important source for manufacturing professionals, research and development engineers in the additive industry, and students and researchers involved in mechanical, mechatronics, automatic control, and materials engineering and science.

Download or read book Additive Manufacturing written by Emrah Celik and published by Walter de Gruyter GmbH & Co KG. This book was released on 2020-07-06 with total page 187 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book covers additive manufacturing of polymers, metals, ceramics, fiber reinforced polymer composites, energy harvesting materials, and biomaterials. Hybrid manufacturing is discussed. Topology optimization methodology is described and finite element software examples are provided. The book is ideal for graduate students and career starters in the industry.