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Article
Publication date: 15 February 2024

Saliq Shamim Shah, Daljeet Singh, Jaswinder Singh Saini and Naveen Garg

This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise…

Abstract

Purpose

This paper aims to study the design and characterization of a 3D printed tetrakaidecahedron cell-based acoustic metamaterial. At present, the mitigation of low-frequency noise involves the utilization of spatially demanding materials for the absorption of sound. These materials lack the ability for targeted frequency control adjustments. Hence, there is a requirement for an approach that can effectively manage low-frequency noise using lightweight and durable materials.

Design/methodology/approach

The CAD model was created in SolidWorks and was manufactured using the Digital Light Processing (DLP) 3D printing technique. Experimental study and numerical simulations examined the metamaterial’s acoustic absorption. An impedance tube with two microphones was used to determine the absorption coefficient of the metamaterial. The simulations were run in a thermoviscous module.

Findings

The testing of acoustic samples highlighted the effects of geometric parameters on acoustic performance. Increment of the strut length by 0.4 mm led to a shift in response to a lower frequency by 500 Hz. Peak absorption rose from 0.461 to 0.690 as the strut diameter was increased from 0.6 to 1.0 mm. Increasing the number of cells from 8 to 20 increased the absorption coefficient and lowered the response frequency.

Originality/value

DLP 3D printing technique was used to successfully manufacture tetrakaidecahedron-based acoustic metamaterial samples. A novel study on the effects of geometric parameters of tetrakaidecahedron cell-based acoustic metamaterial on the acoustic absorption coefficient was conducted, which seemed to be missing in the literature.

Open Access
Article
Publication date: 28 February 2024

Luke Mizzi, Arrigo Simonetti and Andrea Spaggiari

The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved…

Abstract

Purpose

The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved geometric versatility over traditional chiral honeycombs. This paper aims to design and manufacture chiral honeycombs representative of four distinct classes of 2D Euclidean tessellations with hexagonal rotational symmetry using fused-deposition additive manufacturing and experimentally analysed the mechanical properties and failure modes of these metamaterials.

Design/methodology/approach

Finite Element simulations were also used to study the high-strain compressive performance of these systems under both periodic boundary conditions and realistic, finite conditions. Experimental uniaxial compressive loading tests were applied to additively manufactured prototypes and digital image correlation was used to measure the Poisson’s ratio and analyse the deformation behaviour of these systems.

Findings

The results obtained demonstrate that these systems have the ability to exhibit a wide range of Poisson’s ratios (positive, quasi-zero and negative values) and stiffnesses as well as unusual failure modes characterised by a sequential layer-by-layer collapse of specific, non-adjacent ligaments. These findings provide useful insights on the mechanical properties and deformation behaviours of this new class of metamaterials and indicate that these chiral honeycombs could potentially possess anomalous characteristics which are not commonly found in traditional chiral metamaterials based on regular monohedral tilings.

Originality/value

To the best of the authors’ knowledge, the authors have analysed for the first time the high strain behaviour and failure modes of chiral metamaterials based on Euclidean multi-polygonal tessellations.

Details

Rapid Prototyping Journal, vol. 30 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 9 January 2024

Chunfu Wu, Guorui Ye, Yonghong Zhao, Baowen Ye, Tao Wang, Liangmo Wang and Zeming Zhang

Auxetics metamaterials show high performance in their specific characteristics, while the absolute stiffness and strength are much weaker due to substantial porosity. This paper…

Abstract

Purpose

Auxetics metamaterials show high performance in their specific characteristics, while the absolute stiffness and strength are much weaker due to substantial porosity. This paper aims to propose a novel auxetic honeycomb structure manufactured using selective laser melting and study the enhanced mechanical performance when subjected to in-plane compression loading.

Design/methodology/approach

A novel composite structure was designed and fabricated on the basis of an arrowhead auxetic honeycomb and filled with polyurethane foam. The deformation mechanism and mechanical responses of the structure with different structural parameters were investigated experimentally and numerically. With the verified simulation models, the effects of parameters on compression strength and energy absorption characteristics were further discussed through parametric analysis.

Findings

A good agreement was achieved between the experimental and simulation results, showing an evidently enhanced compression strength and energy absorption capacity. The interaction between the auxetic honeycomb and foam reveals to exploit a reinforcement effect on the compression performance. The parametric analysis indicates that the composite with smaller included angel and higher foam density exhibits higher plateau stress and better specific energy absorption, while increasing strut thickness is undesirable for high energy absorption efficiency.

Originality/value

The results of this study served to demonstrate an enhanced mechanical performance for the foam filled auxetic honeycomb, which is expected to be exploited with applications in aerospace, automobile, civil engineering and protective devices. The findings of this study can provide numerical and experimental references for the design of structural parameters.

Details

Rapid Prototyping Journal, vol. 30 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 20 March 2024

Guijian Xiao, Tangming Zhang, Yi He, Zihan Zheng and Jingzhe Wang

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding…

Abstract

Purpose

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

Design/methodology/approach

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Findings

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

Originality/value

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2633-6596

Keywords

Article
Publication date: 1 January 2024

Shrutika Sharma, Vishal Gupta, Deepa Mudgal and Vishal Srivastava

Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to…

Abstract

Purpose

Three-dimensional (3D) printing is highly dependent on printing process parameters for achieving high mechanical strength. It is a time-consuming and expensive operation to experiment with different printing settings. The current study aims to propose a regression-based machine learning model to predict the mechanical behavior of ulna bone plates.

Design/methodology/approach

The bone plates were formed using fused deposition modeling (FDM) technique, with printing attributes being varied. The machine learning models such as linear regression, AdaBoost regression, gradient boosting regression (GBR), random forest, decision trees and k-nearest neighbors were trained for predicting tensile strength and flexural strength. Model performance was assessed using root mean square error (RMSE), coefficient of determination (R2) and mean absolute error (MAE).

Findings

Traditional experimentation with various settings is both time-consuming and expensive, emphasizing the need for alternative approaches. Among the models tested, GBR model demonstrated the best performance in predicting both tensile and flexural strength and achieved the lowest RMSE, highest R2 and lowest MAE, which are 1.4778 ± 0.4336 MPa, 0.9213 ± 0.0589 and 1.2555 ± 0.3799 MPa, respectively, and 3.0337 ± 0.3725 MPa, 0.9269 ± 0.0293 and 2.3815 ± 0.2915 MPa, respectively. The findings open up opportunities for doctors and surgeons to use GBR as a reliable tool for fabricating patient-specific bone plates, without the need for extensive trial experiments.

Research limitations/implications

The current study is limited to the usage of a few models. Other machine learning-based models can be used for prediction-based study.

Originality/value

This study uses machine learning to predict the mechanical properties of FDM-based distal ulna bone plate, replacing traditional design of experiments methods with machine learning to streamline the production of orthopedic implants. It helps medical professionals, such as physicians and surgeons, make informed decisions when fabricating customized bone plates for their patients while reducing the need for time-consuming experimentation, thereby addressing a common limitation of 3D printing medical implants.

Details

Rapid Prototyping Journal, vol. 30 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 18 January 2024

Uğur Kemiklioğlu, Sermet Demir and Caner Yüksel

Adhesively bonded joints are used in many fields, especially in the automotive, marine, aviation, defense and outdoor industries. Adhesive bonding offers advantages over…

Abstract

Purpose

Adhesively bonded joints are used in many fields, especially in the automotive, marine, aviation, defense and outdoor industries. Adhesive bonding offers advantages over traditional mechanical methods, including the ability to join diverse materials, even load distribution and efficient thermal-electrical insulation. This study aims to investigate the mechanical properties of adhesively bonded joints, focusing on adherends produced with auxetic and flat surfaces adhered with varying adhesive thicknesses.

Design/methodology/approach

The research uses three-dimensional (3D)-printed materials, polyethylene terephthalate glycol and polylactic acid, and two adhesive types with ductile and brittle properties for single lap joints, analyzing their mechanical performance through tensile testing. The adhesion region of one of these adherends was formed with a flat surface and the other with an auxetic surface. Adhesively bonded joints were produced with 0.2, 0.3 and 0.4 mm bonding thickness.

Findings

Results reveal that auxetic adherends exhibit higher strength compared to flat surfaces. Interestingly, the strength of ductile adhesives in auxetic bonded joints increases with adhesive thickness, while brittle adhesive strength decreases with thicker auxetic bonds. Moreover, the auxetic structure displays reduced elongation under comparable force.

Originality/value

The findings emphasize the intricate interplay between adhesive type, bonded surface configuration of adherend and bonding thickness, crucial for understanding the mechanical behavior of adhesively bonded joints in the context of 3D-printed materials.

Details

Rapid Prototyping Journal, vol. 30 no. 3
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 9 February 2024

Martin Novák, Berenika Hausnerova, Vladimir Pata and Daniel Sanetrnik

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass…

Abstract

Purpose

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

Design/methodology/approach

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Findings

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

Originality/value

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

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