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Open Access
Article
Publication date: 29 February 2024

Guanchen Liu, Dongdong Xu, Zifu Shen, Hongjie Xu and Liang Ding

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous…

Abstract

Purpose

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Design/methodology/approach

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

Findings

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

Originality/value

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

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: 8 March 2024

Çağın Bolat, Nuri Özdoğan, Sarp Çoban, Berkay Ergene, İsmail Cem Akgün and Ali Gökşenli

This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the…

Abstract

Purpose

This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the literature. The main goal of this endeavor is to create a casting machining-neural network modeling flow-line for real-time foam manufacturing in the industry.

Design/methodology/approach

Samples were manufactured via an industry-based die-casting technology. For the slot milling tests performed with different cutting speeds, depth of cut and lubrication conditions, a 3-axis computer numerical control (CNC) machine was used and the force data were collected through a digital dynamometer. These signals were used as input parameters in neural network modelings.

Findings

Among the algorithms, the scaled-conjugated-gradient (SCG) methodology was the weakest average results, whereas the Levenberg–Marquard (LM) approach was highly successful in foreseeing the cutting forces. As for the input variables, an increase in the depth of cut entailed the cutting forces, and this circumstance was more obvious at the higher cutting speeds.

Research limitations/implications

The effect of milling parameters on the cutting forces of low-cost clay-filled metallic syntactics was examined, and the correct detection of these impacts is considerably prominent in this paper. On the other side, tool life and wear analyses can be studied in future investigations.

Practical implications

It was indicated that the milling forces of the clay-added AA7075 syntactic foams, depending on the cutting parameters, can be anticipated through artificial neural network modeling.

Social implications

It is hoped that analyzing the influence of the cutting parameters using neural network models on the slot milling forces of metallic syntactic foams (MSFs) will be notably useful for research and development (R&D) researchers and design engineers.

Originality/value

This work is the first investigation that focuses on the estimation of slot milling forces of the expanded clay-added AA7075 syntactic foams by using different artificial neural network modeling approaches.

Details

Multidiscipline Modeling in Materials and Structures, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1573-6105

Keywords

Open Access
Article
Publication date: 2 January 2024

Guillermo Guerrero-Vacas, Jaime Gómez-Castillo and Oscar Rodríguez-Alabanda

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using…

Abstract

Purpose

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process.

Design/methodology/approach

PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles.

Findings

PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one.

Originality/value

The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.

Details

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

Keywords

Article
Publication date: 9 February 2024

Rizk Mostafa Shalaby and Mohamed Saad

The purpose of the present work is to study the impacts of rapid cooling and Tb rare-earth additions on the structural, thermal and mechanical behavior of Bi–0.5Ag lead-free…

Abstract

Purpose

The purpose of the present work is to study the impacts of rapid cooling and Tb rare-earth additions on the structural, thermal and mechanical behavior of Bi–0.5Ag lead-free solder for high-temperature applications.

Design/methodology/approach

Effect of rapid solidification processing on structural, thermal and mechanical properties of Bi-Ag lead-free solder reinforced Tb rare-earth element.

Findings

The obtained results indicated that the microstructure consists of rhombohedral Bi-rich phase and Ag99.5Bi0.5 intermetallic compound (IMC). The addition of Tb could effectively reduce the onset and melting point. The elastic modulus of Tb-containing solders was enhanced to about 90% at 0.5 Tb. The higher elastic modulus may be attributed to solid solution strengthening effect, solubility extension, microstructure refinement and precipitation hardening of uniform distribution Ag99.5Bi0.5 IMC particles which can reasonably modify the microstructure, as well as inhibit the segregation and hinder the motion of dislocations.

Originality/value

It is recommended that the lead-free Bi-0.5Ag-0.5Tb solder be a candidate instead of common solder alloy (Sn-37Pb) for high temperature and high performance applications.

Details

Soldering & Surface Mount Technology, vol. 36 no. 2
Type: Research Article
ISSN: 0954-0911

Keywords

Article
Publication date: 11 January 2024

Qiang Sun, Quantong Jiang, Siwei Wu, Chang Liu, Heng Tang, L. Song, Hao Shi, Jizhou Duan and BaoRong Hou

The purpose of this paper is to explore the effect of ZnO on the structure and properties of micro-arc oxidation (MAO) coating on rare earth magnesium alloy under large…

Abstract

Purpose

The purpose of this paper is to explore the effect of ZnO on the structure and properties of micro-arc oxidation (MAO) coating on rare earth magnesium alloy under large concentration gradient.

Design/methodology/approach

The macroscopic and microscopic morphology, thickness, surface roughness, chemical composition and structure of the coating were characterized by different characterization methods. The corrosion resistance of the film was studied by electrochemical and scanning Kelvin probe force microscopy. The results show that the addition of ZnO can significantly improve the compactness and corrosion resistance of the MAO coating, but the high concentration of ZnO will cause microcracks, which will reduce the corrosion resistance to a certain extent.

Findings

When the concentration of zinc oxide is 8 g/L, the compactness and corrosion resistance of the coating are the best, and the thickness of the coating is positively correlated with the concentration of ZnO.

Research limitations/implications

Too high concentration of ZnO reduces the performance of MAO coating.

Practical implications

The MAO coating prepared by adding ZnO has good corrosion resistance. Combined with organic coatings, it can be applied in corrosive marine environments, such as ship parts and hulls. To a certain extent, it can reduce the economic loss caused by corrosion.

Originality/value

The effect of ZnO on the corrosion resistance of MAO coating in electrolyte solution was studied systematically, and the conclusion was new to the common knowledge.

Details

Anti-Corrosion Methods and Materials, vol. 71 no. 2
Type: Research Article
ISSN: 0003-5599

Keywords

Article
Publication date: 19 March 2024

Diana Irinel Baila, Filippo Sanfilippo, Tom Savu, Filip Górski, Ionut Cristian Radu, Catalin Zaharia, Constantina Anca Parau, Martin Zelenay and Pacurar Razvan

The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM…

Abstract

Purpose

The development of new advanced materials, such as photopolymerizable resins for use in stereolithography (SLA) and Ti6Al4V manufacture via selective laser melting (SLM) processes, have gained significant attention in recent years. Their accuracy, multi-material capability and application in novel fields, such as implantology, biomedical, aviation and energy industries, underscore the growing importance of these materials. The purpose of this study is oriented toward the application of new advanced materials in stent manufacturing realized by 3D printing technologies.

Design/methodology/approach

The methodology for designing personalized medical devices, implies computed tomography (CT) or magnetic resonance (MR) techniques. By realizing segmentation, reverse engineering and deriving a 3D model of a blood vessel, a subsequent stent design is achieved. The tessellation process and 3D printing methods can then be used to produce these parts. In this context, the SLA technology, in close correlation with the new types of developed resins, has brought significant evolution, as demonstrated through the analyses that are realized in the research presented in this study. This study undertakes a comprehensive approach, establishing experimentally the characteristics of two new types of photopolymerizable resins (both undoped and doped with micro-ceramic powders), remarking their great accuracy for 3D modeling in die-casting techniques, especially in the production process of customized stents.

Findings

A series of analyses were conducted, including scanning electron microscopy, energy-dispersive X-ray spectroscopy, mapping and roughness tests. Additionally, the structural integrity and molecular bonding of these resins were assessed by Fourier-transform infrared spectroscopy–attenuated total reflectance analysis. The research also explored the possibilities of using metallic alloys for producing the stents, comparing the direct manufacturing methods of stents’ struts by SLM technology using Ti6Al4V with stent models made from photopolymerizable resins using SLA. Furthermore, computer-aided engineering (CAE) simulations for two different stent struts were carried out, providing insights into the potential of using these materials and methods for realizing the production of stents.

Originality/value

This study covers advancements in materials and additive manufacturing methods but also approaches the use of CAE analysis, introducing in this way novel elements to the domain of customized stent manufacturing. The emerging applications of these resins, along with metallic alloys and 3D printing technologies, have brought significant contributions to the biomedical domain, as emphasized in this study. This study concludes by highlighting the current challenges and future research directions in the use of photopolymerizable resins and biocompatible metallic alloys, while also emphasizing the integration of artificial intelligence in the design process of customized stents by taking into consideration the 3D printing technologies that are used for producing these stents.

Details

Rapid Prototyping Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 29 January 2024

Chang Chen, Yuandong Liang, Jiten Sun, Chen Lin and Yehao Wen

The purpose of this paper is to introduce a variable distance pneumatic gripper with embedded flexible sensors, which can effectively grasp fragile and flexible objects.

Abstract

Purpose

The purpose of this paper is to introduce a variable distance pneumatic gripper with embedded flexible sensors, which can effectively grasp fragile and flexible objects.

Design/methodology/approach

Based on the motion principle of the three-jaw chuck and the pneumatic “fast pneumatic network” (FPN), a variable distance pneumatic holder embedded with a flexible sensor is designed. A structural design plan and preparation process of a soft driver is proposed, using carbon nanotubes as filler in a polyurethane (PU) sponge. A flexible bending sensor based on carbon nanotube materials was produced. A static model of the soft driver cavity was established, and a bending simulation was performed. Based on the designed variable distance soft pneumatic gripper, a real-time monitoring and control system was developed. Combined with the developed pneumatic control system, gripping experiments on objects of different shapes and easily deformable and fragile objects were conducted.

Findings

In this paper, a variable-distance pneumatic gripper embedded with a flexible sensor was designed, and a control system for real-time monitoring and multi-terminal input was developed. Combined with the developed pneumatic control system, a measure was carried out to measure the relationship between the bending angle, output force and air pressure of the soft driver. Flexible bending sensor performance test. The gripper diameter and gripping weight were tested, and the maximum gripping diameter was determined to be 182 mm, the maximum gripping weight was approximately 900 g and the average measurement error of the bending sensor was 5.91%. Objects of different shapes and easily deformable and fragile objects were tested.

Originality/value

Based on the motion principle of the three-jaw chuck and the pneumatic FPN, a variable distance pneumatic gripper with embedded flexible sensors is proposed by using the method of layered and step-by-step preparation. The authors studied the gripper structure design, simulation analysis, prototype preparation, control system construction and experimental testing. The results show that the designed flexible pneumatic gripper with variable distance can grasp common objects.

Details

Industrial Robot: the international journal of robotics research and application, vol. 51 no. 2
Type: Research Article
ISSN: 0143-991X

Keywords

Article
Publication date: 14 March 2024

Gülçin Baysal

The aim of this review is to present together the studies on textile-based moisture sensors developed using innovative technologies in recent years.

Abstract

Purpose

The aim of this review is to present together the studies on textile-based moisture sensors developed using innovative technologies in recent years.

Design/methodology/approach

The integration levels of the sensors studied with the textile materials are changing. Some research teams have used a combination of printing and textile technologies to produce sensors, while a group of researchers have used traditional technologies such as weaving and embroidery. Others have taken advantage of new technologies such as electro-spinning, polymerization and other techniques. In this way, they tried to combine the good working efficiency of the sensors and the flexibility of the textile. All these approaches are presented in this article.

Findings

The presentation of the latest technologies used to develop textile sensors together will give researchers an idea about new studies that can be done on highly sensitive and efficient textile-based moisture sensor systems.

Originality/value

In this paper humidity sensors have been explained in terms of measuring principle as capacitive and resistive. Then, studies conducted in the last 20 years on the textile-based humidity sensors have been presented in detail. This is a comprehensive review study that presents the latest developments together in this area for researchers.

Details

International Journal of Clothing Science and Technology, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0955-6222

Keywords

Article
Publication date: 29 February 2024

Jie Wan, Biao Chen, Jianghua Shen, Katsuyoshi Kondoh, Shuiqing Liu and Jinshan Li

The metallic alloys and their components fabricated via laser powder bed fusion (LPBF) suffer from the microvoids formed inevitably due to the extreme solidification rate during…

Abstract

Purpose

The metallic alloys and their components fabricated via laser powder bed fusion (LPBF) suffer from the microvoids formed inevitably due to the extreme solidification rate during fabrication, which are impossible to be removed by heat treatment. This paper aims to remove those microvoids in as-built AlSi10Mg alloys by hot forging and enhance their mechanical properties.

Design/methodology/approach

AlSi10Mg samples were built using prealloyed powder with a set of optimized LPBF parameters, viz. 350 W of laser power, 1,170 mm/s of scan speed, 50 µm of layer thickness and 0.24 mm of hatch spacing. As-built samples were preheated to 430°C followed by immediate pressing with two different thickness reductions of 10% and 35%. The effect of hot forging on the microstructure was analyzed by means of X-ray diffraction, scanning electron microscopy, electron backscattered diffraction and transmission electron microscopy. Tensile tests were performed to reveal the effect of hot forging on the mechanical properties.

Findings

By using hot forging, the large number of microvoids in both as-built and post heat-treated samples were mostly healed. Moreover, the Si particles were finer in forged condition (∼150 nm) compared with those in heat-treated condition (∼300 nm). Tensile tests showed that compared with heat treatment, the hot forging process could noticeably increase tensile strength at no expense of ductility. Consequently, the toughness (integration of tensile stress and strain) of forged alloy increased by ∼86% and ∼24% compared with as-built and heat-treated alloys, respectively.

Originality/value

Hot forging can effectively remove the inevitable microvoids in metals fabricated via LPBF, which is beneficial to the mechanical properties. These findings are inspiring for the evolution of the LPBF technique to eliminate the microvoids and boost the mechanical properties of metals fabricated via LPBF.

Details

Rapid Prototyping Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 24 May 2023

Vijaya Prasad Burle, Tattukolla Kiran, N. Anand, Diana Andrushia and Khalifa Al-Jabri

The construction industries at present are focusing on designing sustainable concrete with less carbon footprint. Considering this aspect, a Fibre-Reinforced Geopolymer Concrete…

Abstract

Purpose

The construction industries at present are focusing on designing sustainable concrete with less carbon footprint. Considering this aspect, a Fibre-Reinforced Geopolymer Concrete (FGC) was developed with 8 and 10 molarities (M). At elevated temperatures, concrete experiences deterioration of its mechanical properties which is in some cases associated with spalling, leading to the building collapse.

Design/methodology/approach

In this study, six geopolymer-based mix proportions are prepared with crimped steel fibre (SF), polypropylene fibre (PF), basalt fibre (BF), a hybrid mixture consisting of (SF + PF), a hybrid mixture with (SF + BF), and a reference specimen (without fibres). After temperature exposure, ultrasonic pulse velocity, physical characteristics of damaged concrete, loss of compressive strength (CS), split tensile strength (TS), and flexural strength (FS) of concrete are assessed. A polynomial relationship is developed between residual strength properties of concrete, and it showed a good agreement.

Findings

The test results concluded that concrete with BF showed a lower loss in CS after 925 °C (i.e. 60 min of heating) temperature exposure. In the case of TS, and FS, the concrete with SF had lesser loss in strength. After 986 °C and 1029 °C exposure, concrete with the hybrid combination (SF + BF) showed lower strength deterioration in CS, TS, and FS as compared to concrete with PF and SF + PF. The rate of reduction in strength is similar to that of GC-BF in CS, GC-SF in TS and FS.

Originality/value

Performance evaluation under fire exposure is necessary for FGC. In this study, we provided the mechanical behaviour and physical properties of SF, PF, and BF-based geopolymer concrete exposed to high temperatures, which were evaluated according to ISO standards. In addition, micro-structural behaviour and linear polynomials are observed.

Details

Journal of Structural Fire Engineering, vol. 15 no. 1
Type: Research Article
ISSN: 2040-2317

Keywords

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