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1 – 10 of over 1000Aditya Kelkar and Bahattin Koc
The objective of this paper is to develop geometric algorithms and planning strategies to enable the development of a novel hybrid manufacturing process, which combines rapidly…
Abstract
Purpose
The objective of this paper is to develop geometric algorithms and planning strategies to enable the development of a novel hybrid manufacturing process, which combines rapidly re‐configurable mold tooling and multi‐axis machining.
Design/methodology/approach
The presented hybrid process combines advantages of both reconfigurable molding and machining processes. The mold's re‐configurability is based on the concept of using an array of discrete pins. By positioning the pins, the reconfigurable molding process allows forming the mold cavity directly from the object's 3D design model, without any human intervention. After a segment of the part is molded using the reconfigurable molding process, a multi‐axis machining operation is used to create accurate parts with better surface finish. Geometric algorithms are developed to decompose the design model into segments based on the part's moldability and machinability. The decomposed features are used for planning the reconfigurable molding and the multi‐axis machining operations.
Findings
Computer implementation and illustrative examples are also presented in this paper. The results showed that the developed algorithms enable the proposed hybrid re‐configurable molding and multi‐axis machining process. The developed decomposition and planning algorithms are used for planning the reconfigurable molding and the multi‐axis machining operations. Owing to the decomposition strategy, more geometrically complex parts can be fabricated using the developed hybrid process.
Originality/value
This paper presents geometric analysis and planning to enable the development of a novel hybrid manufacturing process, which combines rapidly re‐configurable mold tooling and multi‐axis machining. It is expected that the proposed hybrid manufacturing process can produce highly customized parts with better surface finish, and part accuracy, with shorter build times, and reduced setup and tooling costs.
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Radhwan Bin Hussin, Safian Bin Sharif, Shayfull Zamree Bin Abd Rahim, Mohd Azlan Bin Suhaimi, Mohd Tanwyn Bin Mohd Khushairi, Abdellah Abdellah EL-Hadj and Norshah Afizi Bin Shuaib
Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype…
Abstract
Purpose
Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype applications, especially in the development of new products. The purpose of this study is to analyze the current application trends of RT techniques in producing hybrid mold inserts.
Design/methodology/approach
The direct and indirect RT techniques discussed in this paper are aimed at developing a hybrid mold insert using metal epoxy composite (MEC) in increasing the speed of tooling development and performance. An extensive review of the suitable development approach of hybrid mold inserts, material preparation and filler effect on physical and mechanical properties has been conducted.
Findings
Latest research studies indicate that it is possible to develop a hybrid material through the combination of different shapes/sizes of filler particles and it is expected to improve the compressive strength, thermal conductivity and consequently increasing the hybrid mold performance (cooling time and a number of molding cycles).
Research limitations/implications
The number of research studies on RT for hybrid mold inserts is still lacking as compared to research studies on conventional manufacturing technology. One of the significant limitations is on the ways to improve physical and mechanical properties due to the limited type, size and shape of materials that are currently available.
Originality/value
This review presents the related information and highlights the current gaps related to this field of study. In addition, it appraises the new formulation of MEC materials for the hybrid mold inserts in injection molding application and RT for non-metal products.
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Pedro Gonçalves Martinho, Paulo Jorge Bártolo and António Sérgio Pouzada
This paper aims to explore the influence of the materials used in moulding blocks of hybrid moulds on the injection moulding setup and the properties of the mouldings.
Abstract
Purpose
This paper aims to explore the influence of the materials used in moulding blocks of hybrid moulds on the injection moulding setup and the properties of the mouldings.
Design/methodology/approach
An instrumented (pressure and temperature) hybrid mould with exchangeable moulding blocks, produced by rapid prototyping and tooling techniques (RPT), was used to produce polypropylene tubular mouldings. The configuration of the mould was varied with combinations of moulding block materials, namely, an epoxy resin composite processed by vacuum casting and steel. The processing conditions were adjusted to obtained steady processing conditions. The mouldings were assessed in terms of the microstructure and the shrinkage.
Findings
Due to the properties of the moulding block obtained by RPT being different from tool steel, the injection moulding processing conditions and the plastics parts properties are different when hybrid moulds are used. The cycle time depends on the moulding block properties and must be adjusted to the desired running temperature. The morphology of the mouldings is strongly affected by the thermal properties of the moulding block materials. When different materials are used in the core and the cavity asymmetric structures develop in the part. The shrinkage of the mouldings, when resin cores are used is also affected by the deformation of the core caused by the injection pressure.
Originality/value
This paper makes a contribution to understanding the morphology of semi‐crystalline mouldings obtained using hybrid moulds and enhances the importance of the core deformation on the shrinkage of the mouldings.
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Damir Godec, Mladen Šercer and Maja Rujnić‐Sokele
This paper aims to emphasize compared experimental analysis of influence of hybrid and classic moulds on the properties of moulded parts and the processing parameters. Such…
Abstract
Purpose
This paper aims to emphasize compared experimental analysis of influence of hybrid and classic moulds on the properties of moulded parts and the processing parameters. Such analysis enables optimization of processing parameters in case of the hybrid mould.
Design/methodology/approach
Representative moulded part and appropriate hybrid and classic moulds have been designed and manufactured. The experimental work contains a screening design and the main central composite design for analysing the performance of both moulds and moulded parts properties. In case of hybrid mould a numerical optimization of processing parameters was used.
Findings
It was found that hybrid moulds can be successfully applied for production of thin‐wall moulded parts with some limitations. The compressibility of prototype mould inserts was higher compared to classic inserts. The differences in thermal properties of mould inserts materials result in different moulded part properties and mould cavity wall temperature fields. These differences can be reduced by optimizing the processing parameters.
Practical implications
RT technologies can be usefully applied for fast production of moulds for injection moulding. The potential user of hybrid moulds should be aware of the influence of prototype inserts on the moulded part properties. Guidelines for optimization can be used for fast achieving of parameters from optimal processing window.
Originality/value
This paper shows a detailed analysis of influence of hybrid and classic moulds on the thermoplastic moulded part properties. Some of these influences are explained in detail, which was not found in the related papers. In this paper, a further step was made by optimizing the processing parameters in case of hybrid mould.
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P. Mognol, M. Rivette, L. Jégou and T. Lesprier
To propose a method to manufacture a hybrid rapid tool (a multi component tool).
Abstract
Purpose
To propose a method to manufacture a hybrid rapid tool (a multi component tool).
Design/methodology/approach
The part is decomposed into multi component prototype instead of a part made from a single piece. First, this method is based on a topological analysis of the tool. Features are regrouped starting from the numerical definition of the die. Second, the manufacturing possibilities of the high speed milling (HSM), direct metal laser sintering (DMLS) and electro discharge machining (EDM) process are analyzed. Finally this information is synthesized to obtain solutions. This method is validated by industrial example.
Findings
A method is proposed to choose the best manufacturing process in order to optimize the manufacture of a “hybrid rapid tooling” between three processes: HSM, DMLS and EDM. So, it is possible to obtain the different components of the hybrid rapid tooling according to the envisaged process.
Research limitations/implications
The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized.
Practical implications
This method allows the selection of the best process among EDM, HSM and DMLS technologies form manufacturing tools.
Originality/value
The analysis of manufacturing hybrid rapid tooling has not been studied yet.
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Mahesh S. Shinde, Kishor Mahadeorao Ashtankar, Abhaykumar M. Kuthe, Sandeep W. Dahake and Mahesh B. Mawale
This review paper aims to provide an overview of applications of direct rapid manufacturing assisted mold with conformal cooling channels (CCCs) and shows the potential of this…
Abstract
Purpose
This review paper aims to provide an overview of applications of direct rapid manufacturing assisted mold with conformal cooling channels (CCCs) and shows the potential of this technique in different manufacturing processes.
Design/methodology/approach
Key publications from the past two decades have been reviewed.
Findings
This study concludes that direct rapid manufacturing technique plays a dominant role in the manufacturing of mold with complicated CCC structure which helps to improve the quality of final part and productivity. The outcome based on literature review and case study strongly suggested that in the near future direct rapid manufacturing method might become standard procedure in various manufacturing processes for fabrication of complex CCCs in the mold.
Practical implications
Advanced techniques such as computer-aided design, computer-aided engineering simulation and direct rapid manufacturing made it possible to easily fabricate the effective CCC in the mold in various manufacturing processes.
Originality/value
This paper is beneficial to study the direct rapid manufacturing technique for development of the mold with CCC and its applications in different manufacturing processes.
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Praveen Kumar Bonthagorla and Suresh Mikkili
To generate electricity, solar photovoltaic (PV) systems are among the best, most eco-friendly and most cost-effective solutions available. Extraction of maximum possible…
Abstract
Purpose
To generate electricity, solar photovoltaic (PV) systems are among the best, most eco-friendly and most cost-effective solutions available. Extraction of maximum possible electricity from the solar PV system is complicated by a number of factors brought on by the ever-changing weather conditions under which it must operate. Many conventional and evolutionary algorithm-based maximum power point tracking (MPPT) techniques have the limitation of not being able to extract maximum power under partial shade and rapidly varying irradiance. Hence, the purpose of this paper is to propose a novel hybrid slime mould assisted with perturb and observe (P&O) global MPPT technique (HSMO) for the hybrid bridge link-honey comb (BL-HC) configured PV system to enhance the better maximum power during dynamic and steady state operations within less time.
Design/methodology/approach
In this method, a hybridization of two algorithms is proposed to track the true with faster convergence under PSCs. Initially, the slime mould optimization (SMO) algorithm is initiated for exploration of optimum duty cycles and later P&O algorithm is initiated for exploitation of global duty cycle for the DC–DC converter to operate at GMPP and for fast convergence.
Findings
The effectiveness of the proposed HSMO MPPT is compared with adaptive coefficient particle swarm optimization (ACPSO), flower pollination algorithm and SMO MPPT techniques in terms of tracked GMPP, convergence time/tracking speed and efficacy under six complex partial shading conditions. From the results, it is noticed that the proposed algorithm tracks the true GMPP under most of the shading conditions with less tracking time when compared to other MPPT techniques.
Originality/value
This paper proposes a novel hybrid slime mould assisted with perturb and observe (P&O) global MPPT technique (HSMO) for the hybrid BL-HC configured PV system enhance the better maximum power under partial shading conditions (PSCs). This method operated in two stages as SMO for exploration and P&O for exploitation for faster convergence and to track true GMPP under PSCs. The proposed approach largely improves the performance of the MPP tracking of the PV systems. Initially, the proposed MPPT technique is simulated in MATLAB/Simulink environment. Furthermore, an experimental setup has been designed and implemented. Simulation results obtained are validated through experimental results which prove the viability of the proposed technique for an efficient green energy solution.
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M. Rivette, P. Mognol and J.Y. Hascoet
The purpose of this paper is to propose a method to obtain hybrid rapid tools with elementary component assembly.
Abstract
Purpose
The purpose of this paper is to propose a method to obtain hybrid rapid tools with elementary component assembly.
Design/methodology/approach
The authors' method proposes a functional representational model, starting with the product features, analyzed from three points of view: a feasibility analysis; a manufacturing analysis; and an assembly and synthesis analysis. This method, based on CAD STEP AP‐224 data, makes it possible to obtain an exhaustive list of solutions for the module. The work is illustrated with an industrial example. To construct the Assembly Identity Card (AIC) and test the various parameters that influence the quality of the injected parts, a hybrid injection mold has been produced. The methodology associated with the use of this AIC uses a “representation graph”, which makes it possible to propose a set of valid solutions for assembling the various tooling modules. This method is validated by industrial example.
Findings
The product part is decomposed into a multi‐component prototype (MCP), instead of being made as a single part, which optimizes the manufacturing process and enables greater reactivity during the development of the product.
Research limitations/implications
The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized.
Practical implications
This method allows the selection of the best process technologies from manufacturing tools.
Originality/value
The analysis of manufacturing hybrid rapid tooling has not been studied previously.
Details
Keywords
Wenzhen Yang, Johan K. Crone, Claus R. Lønkjær, Macarena Mendez Ribo, Shuo Shan, Flavia Dalia Frumosu, Dimitrios Papageorgiou, Yu Liu, Lazaros Nalpantidis and Yang Zhang
This study aims to present a vision-guided robotic system design for application in vat photopolymerization additive manufacturing (AM), enabling vat photopolymerization AM hybrid…
Abstract
Purpose
This study aims to present a vision-guided robotic system design for application in vat photopolymerization additive manufacturing (AM), enabling vat photopolymerization AM hybrid with injection molding process.
Design/methodology/approach
In the system, a robot equipped with a camera and a custom-made gripper as well as driven by a visual servoing (VS) controller is expected to perceive objective, handle variation, connect multi-process steps in soft tooling process and realize automation of vat photopolymerization AM. Meanwhile, the vat photopolymerization AM printer is customized in both hardware and software to interact with the robotic system.
Findings
By ArUco marker-based vision-guided robotic system, the printing platform can be manipulated in arbitrary initial position quickly and robustly, which constitutes the first step in exploring automation of vat photopolymerization AM hybrid with soft tooling process.
Originality/value
The vision-guided robotic system monitors and controls vat photopolymerization AM process, which has potential for vat photopolymerization AM hybrid with other mass production methods, for instance, injection molding.
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Diana Popescu, Aurelian Zapciu, Cristian Tarba and Dan Laptoiu
This paper aims to propose a new solution for producing customized three-dimensional (3D)-printed flat-shaped splints, which are then thermoformed to fit the patient’s hand. The…
Abstract
Purpose
This paper aims to propose a new solution for producing customized three-dimensional (3D)-printed flat-shaped splints, which are then thermoformed to fit the patient’s hand. The splint design process is automated and is available to clinicians through an online application.
Design/methodology/approach
Patient anthropometric data measured by clinicians are associated with variables of parametric 3D splint models. Once these variables are input by clinicians in the online app, customized stereo lithography (STL) files for both splint and half mold, in the case of the bi-material splint, are automatically generated and become available for download. Bi-materials splints are produced by a hybrid manufacturing process involving 3D printing and overmolding.
Findings
This approach eliminates the need for 3D CAD-proficient clinicians, allows fast generation of customized splints, generates two-dimensional (2D) drawings of splints for verifying shape and dimensions before 3D printing and generates the STL files. Automation reduces splint design time and cost, while manufacturing time is diminished by 3D printing the splint in a flat position.
Practical implications
The app could be used in clinical practice. It meets the demands of mass customization using 3D printing in a field where individualization is mandatory. The solution is scalable – it can be extended to other splint designs or to other limbs. 3D-printed tailored splints can offer improved wearing comfort and aesthetic appearance, while maintaining hand immobilization, allowing visually controlled follow-up for edema and rapidly observing the need for revision if necessary.
Originality/value
An online application was developed for uploading patient measurements and downloading 2D drawings and STL files of customized splints. Different models of splints can be designed and included in the database as alternative variants. A method for producing bi-materials flat splints combining soft and rigid polymers represents another novelty of the research.
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