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1 – 10 of 197Vidyut Raghu Viswanath, Shivashankar Hiremath and Dundesh S. Chiniwar
The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings…
Abstract
Purpose
The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings, such as raster angle, infill and orientation to improve the 3D component qualities while fabricating the sample using a 3D printer. However, the influence of these factors on the characteristics of the 3D parts has not been well explored. Owing to the effect of the different print parameters in fused deposition modeling (FDM) technology, it is necessary to evaluate the strength of the parts manufactured using 3D printing technology.
Design/methodology/approach
In this study, the effect of three print parameters − raster angle, build orientation and infill − on the tensile characteristics of 3D-printed components made of three distinct materials − acrylonitrile styrene acrylate (ASA), polycarbonate ABS (PC-ABS) and ULTEM-9085 − was investigated. A variety of test items were created using a commercially accessible 3D printer in various configurations, including raster angle (0°, 45°), (0°, 90°), (45°, −45°), (45°, 90°), infill density (solid, sparse, sparse double dense) and orientation (flat, on-edge).
Findings
The outcome shows that variations in tensile strength and force are brought on by the effects of various printing conditions. In all possible combinations of the print settings, ULTEM 9085 material has a higher tensile strength than ASA and PC-ABS materials. ULTEM 9085 material’s on-edge orientation, sparse infill, and raster angle of (0°, −45°) resulted in the greatest overall tensile strength of 73.72 MPa. The highest load-bearing strength of ULTEM material was attained with the same procedure, measuring at 2,932 N. The tensile strength of the materials is higher in the on-edge orientation than in the flat orientation. The tensile strength of all three materials is highest for solid infill with a flat orientation and a raster angle of (45°, −45°). All three materials show higher tensile strength with a raster angle of (45°, −45°) compared to other angles. The sparse double-dense material promotes stronger tensile properties than sparse infill. Thus, the strength of additive components is influenced by the combination of selected print parameters. As a result, these factors interact with one another to produce a high-quality product.
Originality/value
The outcomes of this study can serve as a reference point for researchers, manufacturers and users of 3D-printed polymer material (PC-ABS, ASA, ULTEM 9085) components seeking to optimize FDM printing parameters for tensile strength and/or identify materials suitable for intended tensile characteristics.
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Vishal Mishra, Ch Kapil Ror, Sushant Negi and Simanchal Kar
This study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber.
Abstract
Purpose
This study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber.
Design/methodology/approach
The continuous metal fiber composite was 3D printed using recycled and virgin acrylonitrile butadiene styrene-blended filament (RABS-B) in the ratio of 60:40 and postused continuous brass wire (CBW). The 3D printing was done using an in-nozzle impregnation technique using an FFF printer installed with a self-modified nozzle. The tensile and single-edge notch bend (SENB) test samples are fabricated to evaluate the tensile and fracture toughness properties compared with VABS and RABS-B samples.
Findings
The tensile and SENB tests revealed that RABS-B/CBW composite 3D printed with 0.7 mm layer spacing exhibited a notable improvement in Young’s modulus, ultimate tensile strength, elongation at maximum load and fracture toughness by 51.47%, 18.67% and 107.3% and 22.75% compared to VABS, respectively.
Social implications
This novel approach of integrating CBW with recycled thermoplastic represents a significant leap forward in material science, delivering superior strength and unlocking the potential for advanced, sustainable composites in demanding engineering fields.
Originality/value
Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.
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Goksel Saracoglu, Serap Kiriş, Sezer Çoban, Muharrem Karaaslan, Tolga Depci and Emin Bayraktar
The aim of this study is to determine the fracture behavior of wool felt and fabric based epoxy composites and their responses to electromagnetic waves.
Abstract
Purpose
The aim of this study is to determine the fracture behavior of wool felt and fabric based epoxy composites and their responses to electromagnetic waves.
Design/methodology/approach
Notched and unnotched tensile tests of composites made of wool only and hybridized with a glass fiber layer were carried out, and fracture behavior and toughness at macro scale were determined. They were exposed to electromagnetic waves between 8 and 18 GHz frequencies using two horn antennas.
Findings
The keratin and lignin layer on the surface of the wool felt caused lower values to be obtained compared to the mechanical values given by pure epoxy. However, the use of wool felt in the symmetry layer of the laminated composite material provided higher mechanical values than the composite with glass fiber in the symmetry layer due to the mechanical interlocking it created. The use of wool in fabric form resulted in an increase in the modulus of elasticity, but no change in fracture toughness was observed. As a result of the electromagnetic analysis, it was also seen in the electromagnetic analysis that the transmittance of the materials was high, and the reflectance was low throughout the applied frequency range. Hence, it was concluded that all of the manufactured materials could be used as radome material over a wide band.
Practical implications
Sheep wool is an easy-to-supply and low-cost material. In this paper, it is presented that sheep wool can be evaluated as a biocomposite material and used for radome applications.
Originality/value
The combined evaluation of felt and fabric forms of a natural and inexpensive reinforcing element such as sheep wool and the combined evaluation of fracture mechanics and electromagnetic absorption properties will contribute to the evaluation of biocomposites in aviation.
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P. Gunasekar, Anderson A. and Praveenkumar T.R.
Composite materials have revolutionized the aerospace industry by offering superior structural qualities over traditional elements. This study aims to focus on the development and…
Abstract
Purpose
Composite materials have revolutionized the aerospace industry by offering superior structural qualities over traditional elements. This study aims to focus on the development and testing of bamboo natural fiber-based composites enhanced with SiO2 nanoparticles.
Design/methodology/approach
The investigation involved fabricating specimens with varying nanoparticle compositions (0, 10 and 20%) and conducting tensile, flexural, impact and fracture toughness tests. Results indicated significant improvements in mechanical properties with the addition of nanoparticles, particularly at a 10% composition level.
Findings
This study underscores the potential of natural fiber composites, highlighting their environmental friendliness, cost-effectiveness and improved structural properties when reinforced with nanoparticles. The findings suggest an optimal ratio for nanoparticle integration, emphasizing the critical role of precise mixing proportions in achieving superior composite performance.
Originality/value
The tensile strength, flexural strength, impact resistance and fracture toughness exhibited notable enhancements compared with the 0 and 20% nanoparticle compositions. The 10% composition showed the most promising outcomes, showcasing increased strength across all parameters.
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Lida Haghnegahdar, Sameehan S. Joshi, Rohith Yanambaka Venkata, Daniel A. Riley and Narendra B. Dahotre
Additive manufacturing also known as 3D printing is an evolving advanced manufacturing technology critical for the new era of complex machinery and operating systems…
Abstract
Purpose
Additive manufacturing also known as 3D printing is an evolving advanced manufacturing technology critical for the new era of complex machinery and operating systems. Manufacturing systems are increasingly faced with risk of attacks not only by traditional malicious actors such as hackers and cyber-criminals but also by some competitors and organizations engaged in corporate espionage. This paper aims to elaborate a plausible risk practice of designing and demonstrate a case study for the compromised-based malicious for polymer 3D printing system.
Design/methodology/approach
This study assumes conditions when a machine was compromised and evaluates the effect of post compromised attack by studying its effects on tensile dog bone specimens as the printed object. The designed algorithm removed predetermined specific number of layers from the tensile samples. The samples were visually identical in terms of external physical dimensions even after removal of the layers. Samples were examined nondestructively for density. Additionally, destructive uniaxial tensile tests were carried out on the modified samples and compared to the unmodified sample as a control for various mechanical properties. It is worth noting that the current approach was adapted for illustrating the impact of cyber altercations on properties of additively produced parts in a quantitative manner. It concurrently pointed towards the vulnerabilities of advanced manufacturing systems and a need for designing robust mitigation/defense mechanism against the cyber altercations.
Findings
Density, Young’s modulus and maximum strength steadily decreased with an increase in the number of missing layers, whereas a no clear trend was observed in the case of % elongation. Post tensile test observations of the sample cross-sections confirmed the successful removal of the layers from the samples by the designed method. As a result, the current work presented a cyber-attack model and its quantitative implications on the mechanical properties of 3D printed objects.
Originality/value
To the best of the authors’ knowledge, this is the original work from the team. It is currently not under consideration for publication in any other avenue. The paper provides quantitative approach of realizing impact of cyber intrusions on deteriorated performance of additively manufactured products. It also enlists important intrusion mechanisms relevant to additive manufacturing.
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Amit Rana, Sandeep Deshwal, Rajesh and Naveen Hooda
The weld joint mechanical properties of friction stir welding (FSW) are majorly reliant on different input parameters of the FSW machine. The study and optmization of these…
Abstract
Purpose
The weld joint mechanical properties of friction stir welding (FSW) are majorly reliant on different input parameters of the FSW machine. The study and optmization of these parameters is uttermost requirement and aim of this study to increase the suitability of FSW in different manufacturing industries. Hence, the input parameters are optimized through different soft computing methods to increase the considered objective in this study.
Design/methodology/approach
In this research, ultimate tensile strength (UTS), yield strength (YS) and elongation (EL) of FSW prepared butt joints of AA6061 and AA5083 Aluminium alloys materials are investigated as per American Society for Testing and Materials (ASTM E8-M04) standard. The FSW joints were prepared by changing the three input process parameters. To develop experimental run order design matrix, rotatable central composite design strategy was used. Furthermore, genetic algorithm (GA) in combination (Hybrid) with response surface methodology (RSM), artificial neural network (ANN), i.e. RSM-GA, ANN-GA, is exercised to optimize the considered process parameters.
Findings
The maximum value of UTS, YS and EL of test specimens on universal testing machine was measured as 264 MPa, 204 MPa and 14.41%, respectively. The most optimized results (UTS = 269.544 MPa, YS = 211.121 MPa and EL = 17.127%) are obtained with ANN-GA for the considered objectives.
Originality/value
The optimization of input parameters to increase the output objective values using hybrid soft computing techniques is unique in this research paper. The outcomes of this study will help the FSW using manufacturing industries to choose the best optimized parameters set for FSW prepared butt joint with improved mechanical properties.
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Mandeep Singh, Khushdeep Goyal and Deepak Bhandari
The purpose of this paper is to evaluate the effect of titanium oxide (TiO2) and yttrium oxide (Y2O3) nanoparticles-reinforced pure aluminium (Al) on the mechanical properties of…
Abstract
Purpose
The purpose of this paper is to evaluate the effect of titanium oxide (TiO2) and yttrium oxide (Y2O3) nanoparticles-reinforced pure aluminium (Al) on the mechanical properties of hybrid aluminium matrix nanocomposites (HAMNCs).
Design/methodology/approach
The HAMNCs were fabricated via a vacuum die-assisted stir casting route by a two-step feeding method. The varying weight percentages of TiO2 and Y2O3 nanoparticles were added as 2.5, 5, 7.5 and 10 Wt.%.
Findings
Scanning electron microscope images showed the homogenous dispersion of nanoparticles in Al matrix. The tensile strength by 28.97%, yield strength by 50.60%, compression strength by 104.6% and micro-hardness by 50.90% were improved in HAMNC1 when compared to the base matrix. The highest values impact strength of 36.3 J was observed for HAMNC1. The elongation % was decreased by increasing the weight percentage of the nanoparticles. HAMNC1 improved the wear resistance by 23.68%, while increasing the coefficient of friction by 14.18%. Field emission scanning electron microscope analysis of the fractured surfaces of tensile samples revealed microcracks and the debonding of nanoparticles.
Originality/value
The combined effect of TiO2 and Y2O3 nanoparticles with pure Al on mechanical properties has been studied. The composites were fabricated with two-step feeding vacuum-assisted stir casting.
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Baixi Chen, Weining Mao, Yangsheng Lin, Wenqian Ma and Nan Hu
Fused deposition modeling (FDM) is an extensively used additive manufacturing method with the capacity to build complex functional components. Due to the machinery and…
Abstract
Purpose
Fused deposition modeling (FDM) is an extensively used additive manufacturing method with the capacity to build complex functional components. Due to the machinery and environmental factors during manufacturing, the FDM parts inevitably demonstrated uncertainty in properties and performance. This study aims to identify the stochastic constitutive behaviors of FDM-fabricated polylactic acid (PLA) tensile specimens induced by the manufacturing process.
Design/methodology/approach
By conducting the tensile test, the effects of the printing machine selection and three major manufacturing parameters (i.e., printing speed S, nozzle temperature T and layer thickness t) on the stochastic constitutive behaviors were investigated. The influence of the loading rate was also explained. In addition, the data-driven models were established to quantify and optimize the uncertain mechanical behaviors of FDM-based tensile specimens under various printing parameters.
Findings
As indicated by the results, the uncertain behaviors of the stiffness and strength of the PLA tensile specimens were dominated by the printing speed and nozzle temperature, respectively. The manufacturing-induced stochastic constitutive behaviors could be accurately captured by the developed data-driven model with the R2 over 0.98 on the testing dataset. The optimal parameters obtained from the data-driven framework were T = 231.3595 °C, S = 40.3179 mm/min and t = 0.2343 mm, which were in good agreement with the experiments.
Practical implications
The developed data-driven models can also be integrated into the design and characterization of parts fabricated by extrusion and other additive manufacturing technologies.
Originality/value
Stochastic behaviors of additively manufactured products were revealed by considering extensive manufacturing factors. The data-driven models were proposed to facilitate the description and optimization of the FDM products and control their quality.
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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.
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Rania Abdel Gwad Eloriby and Hamdy Mohamed Mohamed
This study aims to assess the efficacy of nano-alumina (nano-Al2O3) in improving the performance of epoxy adhesives used to assemble archaeological glass. The conservators face a…
Abstract
Purpose
This study aims to assess the efficacy of nano-alumina (nano-Al2O3) in improving the performance of epoxy adhesives used to assemble archaeological glass. The conservators face a significant problem in assembling this type of artifact. Therefore, the assembling process is considered one of the important stages that must be taken care of to preserve these artifacts from damage and loss.
Design/methodology/approach
To evaluate the stability of adhesives, the samples were subjected to artificial aging under varying environmental conditions. Some investigative techniques and mechanical testing were used in this study to evaluate the selected materials. It includes a transmission electron microscope, X-ray diffraction, visual assessment, digital microscope, scanning electron microscopy (SEM), color change and tensile strength test.
Findings
The visual evaluation and the digital microscope results showed that the epoxy/nano-Al2O3 greatly resisted artificial aging. Although slight yellowing was present, it did not significantly affect the general appearance of the samples. On the other hand, the pure epoxy sample showed cracks of different sizes on its surface due to aging, as evidenced by SEM examination. Furthermore, epoxy/nano-Al2O3 has a better tensile strength (11.27 MPa) and slight color change (ΔE = 2.06).
Originality/value
The main objective of the experimental study was to identify appropriate adhesive materials that possess key properties such as non-yellowing and improved tensile strength by conducting various tests and evaluations. Ultimately, the goal was to identify materials that could serve as effective adhesives for assembling the archaeological glass.
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