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The purpose of this study is to find the best geometries among the cylindrical, enamel and honeycomb geometries based upon the mechanical properties (tensile test, compression test and shear test). Further this obtained geometry could be used to fabricate products like exoskeleton and its supporting members.

The present research focuses on the mechanical testing of cylindrical, enamel and honeycomb-shaped parts fabricated through multi-jet printing (MJP) process with a wall thickness of 0.26, 0.33, 0.4 and 0.66 mm. The polymer specimens (for tensile, compression and shear tests) were fabricated using a multi-jet fusion process. The experimental results were compared with the numerical modelling. Finally, the optimal geometry was obtained, and the influence of wall thicknesses on various mechanical properties (tensile, compression and shear) was studied.

In comparison to cylindrical, enamel structures the honeycomb structures required less time to fabricate and had lower tensile, compressive and shear strengths. The most efficient geometry for fully functional parts where tensile, compressive and shear forces are present during application – cylindrical geometry is preferred followed by enamel, and then honeycomb. It was found that as the wall thickness of various geometries was increased, their ability to withstand tensile, compressive and shear loads also enhanced. The enamel shape structure exhibits greater strain energy storage capacity than other shape structures for compressive loads, and the strength to resist the compressive load will be lower. In the case of cylindrical geometries for tensile loading, the resisting area toward the loading will be higher in comparison to honeycomb- and enamel-based structures. At the same time, the ability to store the stain energy is less. The results of the tensile, compression and shear load finite element analysis using ANSYS are in agreement with those of the experiments.

From the insight of literature review, it is found that a wide range of work is done on fused deposition modeling (FDM) process. But in comparison to FDM, the MJP provide the better dimensional accuracy and surface properties (Lee et al., 2020). Therefore, it is observed that past research works not incorporated the effect of wall thickness of the embedded geometries on mechanical properties of the part fabricated on MJP (Gibson, n.d.). Hence, in this work, effect of wall thickness on tensile, compression and shear strength is considered as the main factor for the honeycomb, enamel and cylindrical geometries.

The purpose of this paper is to investigate, develop and validate a three‐dimensional modelling strategy for the efficient generation of conformal textile data suitable for additive manufacture.

A series of additive manufactured (AM) textiles samples were modelled using currently available computer‐aided design software to understand the limitations associated with the generation of conformal data. Results of the initial three‐dimensional modelling processes informed the exploration and development of a new dedicated efficient modelling strategy that was tested to understand its capabilities.

The research demonstrates the dramatically improved capabilities of the developed three‐dimensional modelling strategy, over existing approaches by accurately mapping complex geometries described as STL data to a mapping mesh without distortion and correctly matching the orientation and surface normal.

To date the generation of data for AM textiles has been seen as a manual and time‐consuming process. The research presents a new dedicated methodology for the efficient generation of complex and conformal AM textile data that will underpin further research in this area.

Poland’s syndrome patients often seek medical interventions to improve their aesthetic appearances. Design and manufacturing technologies make it possible to produce custom-made implants for such medical conditions. The purpose of this study was to compare the 3D digital geometries that were designed using Magics and Geomagic^® Freeform^® for two anonymous case studies of Poland’s syndrome patients.

Computed tomography data were acquired and processed in Mimics^® to isolate the pectoralis muscles in STL file format. STL files were imported into Magics and Geomagic^® Freeform^® to design 3D digital geometries. Thereafter, comparative analyses were performed of the respective 3D digital geometries.

The angle between the vertical and oblique planes for both sides of the thorax was 6.5° for the female and 14° for the male. The surface areas and volumes of the geometries for the female were smaller than the male. Deviation analyses between the healthy side and reconstructed side of a thorax showed that 73 per cent of the test points for Magics and 78 per cent for Geomagic^® Freeform^® fell in the nominated tolerance region of >−5 and <+5 mm for the female. For the male, it was 83 per cent for Magics and 88 per cent for Geomagic^® Freeform^®.

Geomagic^® Freeform^® provides a more versatile design environment; however, the STL editor Magics may be an option to design 3D geometries for less intricate and less contoured implants.

This was a first attempt to compare the 3D geometries for Poland’s syndrome designed with an STL editor to those designed with a computer-aided design program.

Drilling of carbon fiber reinforced plastic (CFRP) composite plates with high surface quality are of great importance for assembly operations. The article aims to optimize the drill geometry and cutting parameters to improve the surface quality of CFRP composite material. In this study, CFRP plates were drilled with uncoated carbide drill bits with standard and step geometry. Thus, the effects of standard and step drill bits on surface quality have been examined comparatively. In addition, optimum output parameters were determined by Taguchi, ANOVA and multiple decision-making methods.

Drill bit point angles were selected as 90°, 110° and 130°. In cutting parameters, three different cutting speeds (25, 50 and 75 m/min) and three different feeds (0.1, 0.15 and 0.2 mm/rev) were determined. L18 orthogonal sequence was used with Taguchi experimental design. Three important output parameters affecting the surface quality are determined as thrust force, surface roughness and delamination factor. For each output parameter, the effects of drill geometry and cutting parameters were evaluated. Input parameters affecting output parameters were analyzed using the ANOVA method. Output parameters were estimated by creating regression equations. Weights were determined using the analytic hierarchy process (AHP) method, and multiple output parameters were optimized using technique for order preference by Similarity to An ideal solution (TOPSIS).

It has been determined from the experimental results that step drills generate smaller thrust forces than standard drills. However, it has been determined that it creates greater surface roughness and delamination factor. From the Taguchi analysis, the optimum input parameters for Fz step tool geometry, 90° point angle, 75 m/min cutting speed and 0.1 mm/rev feed. For Fd, are standard tool geometry, 90° point angle, 25 m/min cutting speed and 0.1 mm/rev feed and for Ra, are standard tool geometry, 130° point angle, 25 m/min cutting speed and 0.1 mm/rev feed. ANOVA analysis determined that the most important parameter on Fd is the tip angle, with 56.33%. The most important parameter on Ra and Fz was found to be 40.53% and 77.06% tool geometry, respectively. As a result of the optimization with multiple criteria decision-making methods, the test order that gave the best surface quality was found as 4–1-9–5-8–17-2–13-6–16-18–15-11–10-3–12-14. The results of the test number 4, which gives the best surface quality, namely, the thrust force is 91.86 N, the surface roughness is 0.75 µm and the delamination factor is 1.043. As a result of experiment number 14, which gave the worst surface quality, the thrust force was 149.88 N, the surface roughness was 3.03 µm and the delamination factor was 1.163.

Surface quality is an essential parameter in the drilling of CFRP plates. Cutting tool geometry comes first among the parameters affecting this. Therefore, different cutting tool geometries are preferred. A comparison of these cutting tools is discussed in detail. On the other hand, thrust force, delamination factor and surface roughness, which are the output parameters that determine the surface quality, have been optimized using the TOPSIS and AHP method. In this way, this situation, which seems complicated, is presented in a plain and understandable form.

In the experiments, cutting tools with different geometries are included. Comparatively, its effects on surface quality were examined. The hole damage mechanism affecting the surface quality is discussed in detail. The results were optimized by evaluating Taguchi, ANOVA, TOPSIS and AHP methods together.

The purpose of the paper is to study natural convection within porous square and triangular geometries (design 1: regular isosceles triangle, design 2: inverted isosceles triangle) subjected to discrete heating with various locations of double heaters along the vertical (square) or inclined (triangular) arms.

Galerkin finite element method is used to solve the governing equations for a wide range of modified Darcy number, Da_m = 10⁻⁵–10⁻² with various fluid saturated porous media, Pr_m = 0.015 and 7.2 at a modified Rayleigh number, Ra_m = 10⁶ involving the strategic placement of double heaters along the vertical or inclined arms (types 1-3). Adaptive mesh refinement is implemented based on the lengths of discrete heaters. Finite element based heat flow visualization via heatlines has been adopted to study heat distribution at various portions.

The strategic positioning of the double heaters (types 1-3) and the convective heatline vortices depict significant overall temperature elevation at both Da_m = 10⁻⁴ and 10⁻² compared to type 0 (single heater at each vertical or inclined arm). Types 2 and 3 are found to promote higher temperature uniformity and greater overall temperature elevation at Da_m = 10⁻². Overall, the triangular design 2 geometry is also found to be optimal in achieving greater temperature elevation for the porous media saturated with various fluids (Pr_m).

Multiple heaters (at each side [left or right] wall) result in enhanced temperature elevation compared to the single heater (at each side [left or right] wall). The results of the current work may be useful for the material processing, thermal storage and solar heating applications.

The heatline approach is used to visualize the heat flow involving double heaters along the side (left or right) arms (square and triangular geometries) during natural convection involving porous media. The heatlines depict the trajectories of heat flow that are essential for thermal management involving larger thermal elevation. The mixing cup or bulk average temperature values are obtained for all types of heating (types 0-3) involving all geometries, and overall temperature elevation is examined based on higher mixing cup temperature values.

The impact of laser peening on curved geometries is not fully comprehended. The purpose of this paper is to explain the action of laser peening on curved components (concave and convex shapes for cylindrical and spherical geometries) by means of shock wave mechanics.

An analytical formulation is derived based on the plasticity incurred inside the material and the results are compared with the prediction by numerical simulation.

A near-linear relationship is observed between curvature and compressive residual stress; an increasing trend was observed for concave models and a decreasing trend was observed for convex models. The consistency in the analytical formulation with the simulation model indicates the behavior of laser peening for curved geometries.

The differences observed in the residual stresses for spherical and cylindrical geometries are primarily due to the effect of Rayleigh waves. This paper illustrates the importance of understanding the physics behind laser peening of curved geometries.

The mixing of fuel and air plays a pivotal role in enhancing combustion in supersonic regime. Proper mixing stabilizes the flame and prevents blow-off. Blow-off is due to the shorter residence time of fuel and air in the combustor, as the flow is in supersonic regime. The flame is initiated in the local subsonic region created using a flameholder within the supersonic combustor. This study aims to design an effective flameholder which increases the residence time of fuel in the combustor allowing proper combustion preventing blow-off and other instabilities.

The geometry of the strut-based flameholder is altered in the present study to induce a streamwise motion of the fluid downstream of the strut. The streamwise motion of the fluid is initiated by the ramps and grooves of the strut geometry. The numerical simulations were carried out using ANSYS Fluent and are validated against the available experimental and numerical results of cold flow with hydrogen injection using plain strut as the flameholder. In the present study, numerical investigations are performed to analyse the effect on hydrogen injection in strut-based flameholders with ramps and converging grooves using Reynolds-averaged Navier–Stokes equation coupled with Menter’s shear stress transport k-ω turbulence model. The analysis is done to determine the effect of geometrical parameters and flow parameter on the flow structures near the base of the strut where thorough mixing takes place. The geometrical parameters under consideration include the ramp length, groove convergence angle, depth of the groove, groove compression angle and the Mach number. Two different strut configurations, namely, symmetric and asymmetric struts were also studied.

Higher turbulence and complex flow structures are visible in asymmetric strut configuration which develops better mixing of hydrogen and air compared to symmetric strut configuration. The variation in the geometric parameters develop changes in the fluid motion downstream of the strut. The fluid passing through the converging grooves gets decelerated thereby reducing the Mach number by 20% near the base of the strut compared to the straight grooved strut. The shorter ramps are found to be more effective, as the pressure variation in lateral direction is carried along the strut walls downstream of the strut increasing the streamwise motion of the fluid. The decrease in the depth of the groove increases the recirculation zone downstream of the strut. Moreover, the increase in the groove compression angle also increases the turbulence near the base of the strut where the fuel is injected. Variation in the injection port location increases the mixing performance of the combustor by 25%. The turbulence of the fuel jet stream is considerably changed by the increase in the injection velocity. However, the change in the flow field properties within the flow domain is marginal. The increase in fuel mass flow rate brings about considerable change in the flow field inducing stronger shock structures.

The present study identifies the optimum geometry of the strut-based flameholder with ramps and converging grooves. The reaction flow modelling may be performed on the strut geometry incorporating the design features obtained in the present study.

Currently on additive manufacturing, extensive research is directed toward mitigating the main challenges associated with multi-material in fused filament fabrication which has a weak bonding strength between dissimilar materials. Low interfacial bonding strength leads to defects, anisotropy and temperature gradient in materials which negatively impact the mechanical performance of the multi-material prints. The purpose of this study was to assess the performance of different interface geometry designs in terms of the mechanical properties of the specimens.

Tensile test specimens were printed using: mono-material without a boundary interface, mono-material with the interface geometries (Face-to-face; U-shape; T-shape; Dovetail; Encapsulation; Mechanical interlocking; and Overlap) and multi-material with the interface geometries. The materials chosen with high and low compatibility were Tough polylactic acid (PLA) and TPU.

The main results of this study indicate that the interface geometries with the mechanical constriction between materials provide better structural integrity to the specimens. Moreover, in the case of the mono-material parts, the most effective interface design was the mechanical interlocking for both Tough PLA and TPU. On the other hand, in the case of multi-material specimens, the encapsulation showed the highest ultimate tensile strength, whereas the overlap and T-shape presented more robust bonding.

This study examines the mechanical performance, particularly tensile strength, strain at break, Young’s modulus and yield strength of different interface designs which were not studied in the previous studies.

Rotor shape optimization is crucial in designing synchronous reluctance machines (SynRMs) because the machine performance is directly proportional to the rotor’s magnetic saliency ratio. The rotor geometry in synchronous reluctance machines is complex, and many geometrical parameters must be optimized. When fluid flux-barrier geometry is desirable, using analytic equations to prepare the rotor geometry for finite element analysis could be tedious. This paper aims to provide a robust numerical procedure to draw the fluid flux-barrier geometry in transversally laminated radial flux inner and outer rotor SynRMs by directly solving the magnetic vector potential equation using the finite difference method..

In this paper, the goal is to have a robust procedure for drawing the rotor geometry for an arbitrary number of slots (Ns), poles (p) and flux-barrier layers (Nfb). Therefore, this paper targeted several combinations to investigate the performance of the proposed algorithm. The MATLAB software is used to implement the proposed algorithm. The ANSYS Maxwell software is used for counterpart finite element simulation to check the correctness of the results derived by the proposed method.

Several inner and outer rotor SynRMs considering a different number of poles and a different number of flux-barrier layers per pole are studied to investigate the performance of the proposed algorithm. Results corresponding to each case are presented, and it is shown that the method is robust, flexible and fast enough, which could be used for the generation of the rotor geometry for the finite element analysis effectively.

The value of the proposed algorithm is its simplicity and straightforwardness in its implementation for the preparation of the rotor geometry with the desired fluid flux-barrier layer curvature resolution suitable for the finite element analysis. The procedure presented in this paper is based on the ideal magnetic loading concept, and in future works, a similar idea could be used for linear and axial flux SynRMs.

This study aims to examine the feasibility of feedforward actuation of the recoater blade position to alleviate the resin surface non-uniformity while moving over deep-to-shallow transitions of submerged (already cured) geometric features.

A two-dimensional computational fluid dynamics (CFD) model has been used to determine optimized blade actuation protocols to minimize the resin surface non-uniformity. An experimental setup has been designed to validate the feasibility of the proposed protocol in practice.

A developed protocol for the blade height actuation is applied to a rectangular stair-like configuration of the underlying part geometry. The evaluation of the actuation protocol revealed the importance of two physical length scales, the capillary length and the size of the flow recirculation cell below in the liquid resin layer below the blade. They determine, together with the length scales defining the topography (horizontal extent and depth), the optimal blade trajectory. This protocol has also shown its efficiency for application to more complicated shapes (and, potentially, for any arbitrary geometry).

This study shows that incorporation of a feedforward control scheme in the recoating system might significantly reduce (by up to 80%) the surface unevenness. Moreover, this improvement of performances does not require major modifications of the existing architecture.

The results presented in this work demonstrate the benefits of the integration of the feedforward control to minimize the leading edge bulges over underlying part geometries in stereolithography.