scholarly journals Evaluation and optimisation of a slurry-based layer casting process in additive manufacturing using multiphase simulations and spatial reconstruction

2021 ◽  
Author(s):  
P. Erhard ◽  
A. Seidel ◽  
J. Vogt ◽  
W. Volk ◽  
D. Günther
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Fine Particles ◽  
High Surface ◽  
Casting Process ◽  
Spatial Reconstruction ◽  
Novel Method ◽  
Slurry Layer ◽  
High Level

AbstractSlurry-based 3D printing allows ceramic green bodies to be fabricated at high packing densities. In contrast to powder-based binder jetting, full densification of printed parts can be achieved in a subsequent sintering step as fine particles dispersed in a suspension are cast and compacted. Slurry-based 3D printing is thus expected to overcome the application limits of the powder-based alternative in metal casting in terms of unfavorable properties like high surface roughness, low density and low mechanical strength. To ensure stress-free drying and therefore high qualities of the compounds made in layers, it is crucial to fabricate single layers with a high level of homogeneity. This paper presents a CFD model based on the open-source simulation environment OpenFOAM to predict the resulting homogeneity of a cast slurry layer with defined parameter sets or coater geometries using the Volume-Of-Fluid method. Moreover, a novel method of spatial reconstruction is proposed to evaluate the surface quality of layers on a minimised computional demand. By comparing the results of the simulation with the real macroscopic behaviour determined in experiments, the approach is found to be a useful tool for suggesting suitable parameters and coater geometries for processing slurries. A precise reconstruction of the outline of the coating area with different process parameters and an approximate prediction of the effect on surface roughness was achieved.

scholarly journals The Influence of Different Slicer Software on 3d Printing Products Accuracy and Surface Roughness

2021 ◽  
Vol 12 (2) ◽  
pp. 371-380
Author(s):  
Sally Cahyati ◽  
◽  
Haris Risqy Aziz
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
High Surface ◽  
3D Printer ◽  
Layer By Layer ◽  
Additive Manufacturing Technology ◽  
Printing Machine

Rapid Prototyping (RP) is a manufacturing process that produces a 3D model CAD to be a real product rapidly by using additive manufacturing technology. In this case, the product will print layer by layer uses a 3D printer machine. The 3D printer requires slicer software to convert CAD data into data that a 3D printer machine can read. Research is done to analyze the effect of three kinds of slicer software on 3D printing objects on the accuracy and surface roughness of the product. The 3D model CAD is sliced using three different slicer software, namely Ideamaker, Repetier Host, and Cura. The slice model result from each slicer will be printed on a 3D printer machine with the same process parameters to be compared. Then the product's dimensional and surface roughness will be measured to determine the effect of each slicer on product quality. The best quality of the product reflected the most suitable slicer software for the 3D printing machine that used. The best results achieved by Cura slicer because it has resulted in small dimensional deviations (max 0,0308±0,0079) and stabile high surface roughness of the product (max 1,585+059).

scholarly journals Mechanical Characterization and Thermodynamic Analysis of Laser-Polished Landscape Design Products Using 3D Printing

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2601
Author(s):  
Yue Ba ◽  
Yu Wen ◽  
Shibin Wu
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
High Surface ◽  
Landscape Design ◽  
Laser Polishing ◽  
Fused Deposition ◽  
Design Structure ◽  
3D Printed ◽  
Stability And Accuracy

Recent innovations in 3D printing technologies and processes have influenced how landscape products are designed, built, and developed. In landscape architecture, reduced-size models are 3D-printed to replicate full-size structures. However, high surface roughness usually occurs on the surfaces of such 3D-printed components, which requires additional post-treatment. In this work, we develop a new type of landscape design structure based on the fused deposition modeling (FDM) technique and present a laser polishing method for FDM-fabricated polylactic acid (PLA) mechanical components, whereby the surface roughness of the laser-polished surfaces is reduced from over Ra 15 µm to less than 0.25 µm. The detailed results of thermodynamics and microstructure evolution are further analyzed during laser polishing. The stability and accuracy of the results are evaluated based on the standard deviation. Additionally, the superior tensile and flexural properties are examined in the laser-polished layer, in which the ultimate tensile strength (UTS) is increased by up to 46.6% and the flexural strength is increased by up to 74.5% compared with the as-fabricated components. Finally, a real polished landscape model is simulated and optimized using a series of scales.

scholarly journals AI-based localization and classification of skin disease with erythema

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Ha Min Son ◽  
Wooho Jeon ◽  
Jinhyun Kim ◽  
Chan Yeong Heo ◽  
Hye Jin Yoon ◽  
...  
Keyword(s):  
Neural Network ◽  
Skin Diseases ◽  
Classification Model ◽  
Screening Tests ◽  
Sensitivity Score ◽  
Common Skin ◽  
Novel Method ◽  
Improved Performance ◽  
High Level

AbstractAlthough computer-aided diagnosis (CAD) is used to improve the quality of diagnosis in various medical fields such as mammography and colonography, it is not used in dermatology, where noninvasive screening tests are performed only with the naked eye, and avoidable inaccuracies may exist. This study shows that CAD may also be a viable option in dermatology by presenting a novel method to sequentially combine accurate segmentation and classification models. Given an image of the skin, we decompose the image to normalize and extract high-level features. Using a neural network-based segmentation model to create a segmented map of the image, we then cluster sections of abnormal skin and pass this information to a classification model. We classify each cluster into different common skin diseases using another neural network model. Our segmentation model achieves better performance compared to previous studies, and also achieves a near-perfect sensitivity score in unfavorable conditions. Our classification model is more accurate than a baseline model trained without segmentation, while also being able to classify multiple diseases within a single image. This improved performance may be sufficient to use CAD in the field of dermatology.

scholarly journals Study of the Effect of Carbon on the Contraction of Hypo-Peritectic Steels during Initial Solidification by Surface Roughness

Metals ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 982 ◽  
Author(s):  
Dazhi Pu ◽  
Guanghua Wen ◽  
Dachao Fu ◽  
Ping Tang ◽  
Junli Guo
Keyword(s):  
Surface Roughness ◽  
Cooling Rate ◽  
Solidification Process ◽  
Casting Process ◽  
Continuous Casting Process ◽  
Peritectic Steel ◽  
Laser Confocal Microscope ◽  
Initial Solidification

In the continuous casting process, the shrinkage of the peritectic phase transition during the initial solidification process has an important influence on the surface quality of peritectic steel. The initial solidification process of 0.10C%, 0.14C%, and 0.16C% peritectic steels was observed in situ by a high temperature laser confocal microscope, and the contraction degree during initial solidification was characterized by surface roughness. The results showed that under the cooling rate of 20 °C/s, the surface roughness value Ra(δ/γ) of 0.10C% peritectic steel was 32 μm, the Ra(δ/γ) value of 0.14C% peritectic steel was 25 μm, and the Ra(δ/γ) value of 0.16C% peritectic steel was 17 μm. With increasing carbon content, the contraction degree of the δ→γ transformation decreased, and the value of the surface roughness Ra(δ/γ) declined. Therefore, surface roughness can characterize the contraction degree of the δ→γ transformation in the initial solidification process of peritectic steel under the condition of a large cooling rate.

scholarly journals Experimental studies of the quality of embossed characters of the Braille alphabet

2016 ◽  
Vol 64 (3) ◽  
pp. 607-614
Author(s):  
R. Barczyk ◽  
D. Jasińska-Choromańska
Keyword(s):  
Surface Roughness ◽  
Statistical Analysis ◽  
3D Printing ◽  
Rapid Prototyping ◽  
Experimental Studies ◽  
Printed Text ◽  
Blind Persons ◽  
Blind Individuals

Abstract The paper presents studies pertaining to the quality of embossed characters of the Braille alphabet used, among other applications, for tagging drug labels. The following parameters of embossed inscriptions were measured: height, diameter of the dots and surface roughness (18 samples with various combinations of their values). 48 blind individuals assessed the quality of the printed text. Statistical analysis proved that a text with dots having height of 0.9 millimeter, diameter of 1.6 millimeters and roughness Ra of about 1 micrometer to be the best. The samples had been made using two different methods of rapid prototyping: PolyJet and SLS. 3D printing is increasingly popular and the studies proved the usefulness of these methods for labeling with embossed inscriptions, due to the repeatability, durability and quality they ensure. The assessing group of blind individuals was comprised of 24 persons 14–17 years old and other 24 persons aged over 60 who were not proficient in reading Braille alphabet, This allows to conclude that a text featuring the above values of the parameters will be easy to read for the majority of blind persons.

scholarly journals Surface Roughness Investigation of Poly-Jet 3D Printing

Mathematics ◽  
2020 ◽  
Vol 8 (10) ◽  
pp. 1758
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Nikolaos Vaxevanidis ◽  
John Kechagias
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Surface Quality ◽  
Back Propagation ◽  
Physical Models ◽  
Layer By Layer ◽  
Linear Regression Models ◽  
Feed Forward Back Propagation ◽  
The Impact

An experimental investigation of the surface quality of the Poly-Jet 3D printing (PJ-3DP) process is presented. PJ-3DP is an additive manufacturing process, which uses jetted photopolymer droplets, which are immediately cured with ultraviolet lamps, to build physical models, layer-by-layer. This method is fast and accurate due to the mechanism it uses for the deposition of layers as well as the 16 microns of layer thickness used. Τo characterize the surface quality of PJ-3DP printed parts, an experiment was designed and the results were analyzed to identify the impact of the deposition angle and blade mechanism motion onto the surface roughness. First, linear regression models were extracted for the prediction of surface quality parameters, such as the average surface roughness (Ra) and the total height of the profile (Rt) in the X and Y directions. Then, a Feed Forward Back Propagation Neural Network (FFBP-NN) was proposed for increasing the prediction performance of the surface roughness parameters Ra and Rt. These two models were compared with the reported ones in the literature; it was revealed that both performed better, leading to more accurate surface roughness predictions, whilst the NN model resulted in the best predictions, in particular for the Ra parameter.

scholarly journals Dimensionless analysis for modelling surface finish in conventional investment casting

2016 ◽  
Vol 45 (2) ◽  
pp. 123-129 ◽  
Author(s):  
Rupinder Singh ◽  
Sunpreet Singh
Keyword(s):  
Mathematical Model ◽  
Surface Finish ◽  
Investment Casting ◽  
Casting Process ◽  
Dimensionless Analysis ◽  
Slurry Layer ◽  
High Level ◽  
Main Effects ◽  
Shed Light ◽  
Study Application

High level surface finish (SF) achievement is one of the major advantages of conventional investment casting process. Not much work hitherto has been reported for modeling the SF in conventional investment casting of industrial components. In the present study application of dimensionless analysis, has been made for developing a mathematical model for SF. Three input process parameters (namely: molten metal pouring temperature (PT), slurry layer’s combination (LC) and volume/surface-area (V/A) ratio of cast components) were judicially selected to give SF as output. This study provide main effects of these input parameters on SFand shed light on the SF mechanism in conventional investment casting. The comparison of mathematical model with experimental results has been made for validation of model.

Development of polymer abrasive medium for nanofinishing of microholes on surgical stainless steel using abrasive flow finishing process

2019 ◽  
Vol 234 (3) ◽  
pp. 355-370 ◽  
Author(s):  
Sachin Singh ◽  
M Ravi Sankar
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
High Surface ◽  
Machining Process ◽  
Abrasive Medium ◽  
Finishing Process ◽  
Drug Eluting ◽  
Finishing Processes ◽  
Abrasive Flow Finishing

The finishing operation completes the manufacturing cycle of a component. Depending on the level of finish (micro and nano) required on the component surface, different finishing processes are employed. Several components employed in medical, automotive and chemical industries use different types of passages for the flow of fluid. The surface roughness of such passages decides the functionality of the component. Drug-eluting stents are one of the recent advancements in the medical industry. They possess microholes for release of the drugs to the point of cure. Microholes are mostly fabricated by thermal-based micromachining processes that generate metallurgically destroyed surface layers with high surface roughness. Later, these are polished using chemical or electrochemical polishing techniques, which chemically destroy the quality of the surface. These metallurgically and chemically modified (destroyed/changed) rough surfaces on the microhole wall can cause contamination of the drug. So in this article, microholes of diameter 850 ± 30 µm are fabricated in surgical stainless steel (SS 316L) workpieces using the electric discharge micromachining process. Machined microholes are finished by employing a non-traditional finishing process called the abrasive flow finishing process. Instead of using a commercially available expensive abrasive flow finishing medium, the economic medium is fabricated in-house, and its rheological study is carried out. Machining process produces microholes with a surface roughness of about 1.40 ± 0.10 µm. Later, by finishing of microholes with the abrasive flow finishing process, the surface roughness is reduced to 150 nm (percentage surface roughness improvement of about 88.53%). Therefore, the abrasive flow finishing process is a viable alternative to chemical-based polishing processes as it removes the recast layer and achieves nanosurface roughness.

scholarly journals Facile bacterial cellulose nanofibrillation for the development of plasmonic paper sensor

2020 ◽  
Author(s):  
Agnes Purwidyantri ◽  
Myrtha Karina ◽  
Chih-Hsien Hsu ◽  
Yoice Srikandace ◽  
Briliant Adhi Prabowo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Bacterial Cellulose ◽  
Limit Of Detection ◽  
High Surface ◽  
Textural Properties ◽  
Food Product ◽  
Casting Process ◽  
Sers Substrate ◽  
Paper Sheet ◽  
Plasmonic Sensor

In this present work, a plasmonic sensor is developed through an extremely cheap cellulose-based source, widely known as a food product, nata de coco (NDC). Capturing its interesting features, such as innate surface roughness from naturally grown cellulose during its fermentation period, the engineering and modulation of NDC fibril size and properties were attempted through a high-pressure homogenization (HPH) treatment to obtain highly dense nanofibrils. After the transformation into a thin, paper-sheet form through a casting process, the homogenized bacterial cellulose (HBC) resulting from HPH was compared with the normally agitated bacterial cellulose (BC) pulp and decorated with silver nanoparticles (AgNPs) to produce plasmonic papers, for further application as surface-enhanced Raman scattering (SERS) substrate. As demonstrated in the measurement of Rhodamine 6G (R6G) molecule, the plasmonic HBC paper sheet provided more prominent SERS signals than the plasmonic BC due to its high surface roughness and improved textural properties from the nanofibrillation process favoring better adsorption of AgNPs and effective SERS hotspots generation. The plasmonic HBC obtained a 2 order higher estimated SERS enhancement factor over the plasmonic BC with a limit of detection of approximately 92 fM. Results denote that the proposed approach provides a new, green-synthesis route toward the exploration of biodegradable sources integrated into an inexpensive and simple nanostructuring process for the production of flexible, paper-based, plasmonic sensors.

scholarly journals Design guidelines for plastic casting using 3D printing

2020 ◽  
Vol 15 ◽  
pp. 155892502091603 ◽  
Author(s):  
Paweł Zmarzły ◽  
Damian Gogolewski ◽  
Tomasz Kozior
Keyword(s):  
Surface Layer ◽  
3D Printing ◽  
Textile Industry ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Design Guidelines ◽  
Design Stage ◽  
Technological Inheritance ◽  
Finished Sample

The main aim of the presented tests was to assess the possibility of using 3D printing and casting material to produce casting molds and prototypes, especially in production of existing models. The analysis was based on the assessment of dimensional accuracy and quality of the surface layer of a finished prototype and the intermediate elements made during the production process. The mold was made using the PolyJet Matrix additive technology, and then a silicone mold was cast which was used to prepare a finished sample for testing in accordance with the design assumptions. Based on the results of metrological measurements, the phenomenon of technological inheritance in terms of error transfer in the foundry industry was evaluated. The measurements obtained suggest that in case of casting process, the hereditary features are transferred from individual casting processes, which is especially prominent in the case of surface texture quality. This confirms the occurrence of the phenomenon of the so-called technological inheritance and the need to analyze it. The results of the tests can be a guide for technologists who design molds, core boxes, and casting models, concerning the corrections (shrinkage) that need to be introduced at the design stage in order to obtain a product (casting) of satisfactory dimensional accuracy and quality of the surface layer. The result can also be useful for casting materials reinforced with glass fiber, carbon fiber, which are common materials in 3D printing and textile industry.

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