Finite Element Simulation of Localized Electrochemical Deposition for Maskless Electrochemical Additive Manufacturing

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Anne M. Brant ◽  
Murali M. Sundaram ◽  
Abishek B. Kamaraj
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Three Dimensional ◽  
Deposition Process ◽  
Specific Process ◽  
Manufacturing Technique ◽  
Element Simulation ◽  
Interelectrode Gap ◽  
Linear And Nonlinear ◽  
High Control

Localized electrodeposition (LED) was explored as an additive manufacturing technique with high control over process parameters and output geometry. The effect of variation of process parameters and changing boundary conditions during the deposition process on the output geometry was observed through simulation and experimentation. Trends were found between specific process parameters and output geometries in the simulations; trends varied between linear and nonlinear, and certain process parameters such as voltage and interelectrode gap were found to have a greater influence on the output than others. The simulations were able to predict the output width of deposition of experiments in an error of 8–30%. The information gained from this research allows for greater understanding of LED output, so that it can potentially be applied as an additive manufacturing technique of complex three-dimensional (3D) parts on the microscale.

Towards Assembly-Free Methods for Additive Manufacturing Simulation

2015 ◽  
Author(s):  
Anirudh Krishnakumar ◽  
Krishnan Suresh ◽  
Aaditya Chandrasekar
Keyword(s):  
Additive Manufacturing ◽  
Stiffness Matrix ◽  
Deposition Process ◽  
Implementation Challenges ◽  
Advantages And Disadvantages ◽  
Material Deposition ◽  
Element Simulation ◽  
Non Linear ◽  
Global Stiffness Matrix ◽  
Linear Systems Of Equations

There is significant interest today in the finite element simulation of various Additive Manufacturing (AM) processes. AM simulation is time-dependent, inherently non-linear, and involves multiple physics. In addition, repeated meshing and insertion of new elements during material deposition can pose significant implementation challenges. Currently, AM simulation is handled either through a ‘quiet’ approach or an ‘inactive’ approach. In the quiet approach, all finite elements within the workspace are assembled into the global stiffness matrix, and the elements yet to be deposited are assigned ‘void’ material properties. In the inactive approach, only the elements that have been deposited are assembled into the global stiffness matrix. The advantages and disadvantages of the two methods are well documented. In this paper, we propose a voxel-based, assembly-free framework for AM simulation. This framework presents several advantages including. (1) The workspace is meshed only once at the start of the simulation, (2) addition and deletion of elements is trivial, (3) reduced memory requirement as the global stiffness matrix is never assembled and (4) the underlying linear systems of equations can be solved efficiently through assembly-free methods. We demonstrate the framework here by simulating transient non-linear thermal behaviour of a laser deposition process, with material deposition.

Customizing Food with an Additive Manufacturing Technology

2012 ◽  
Vol 713 ◽  
pp. 43-48
Author(s):  
L. Serenó ◽  
J. Delgado ◽  
Joaquim de Ciurana
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Three Dimensional ◽  
Manufacturing Technology ◽  
Manufacturing Costs ◽  
Three Dimensional Objects ◽  
Additive Manufacturing Technology ◽  
Qualified Personnel ◽  
Broad Variety ◽  
Traditional Technologies

The development of open Additive Manufacturing (AM) technologies, such as the Fab@Home system, has emerged as a freeform approach capable of producing complex three-dimensional objects with a broad variety of materials. The main objective of this work is to analyze and optimize the manufacturing capacity of this system when producing 3D edible objects. A new heated syringe deposition tool was developed and several process parameters were optimized to adapt this technology to consumers needs. The results revealed in this study show the potential of this system to produce customized edible objects without qualified personnel knowledge, therefore saving manufacturing costs compared to traditional technologies.

scholarly journals A Hybrid Process Integrating Reverse Engineering, Pre-Repair Processing, Additive Manufacturing, and Material Testing for Component Remanufacturing

Materials ◽  
2019 ◽  
Vol 12 (12) ◽  
pp. 1961 ◽  
Author(s):  
Xinchang Zhang ◽  
Wenyuan Cui ◽  
Wei Li ◽  
Frank Liou
Keyword(s):  
Heat Treatment ◽  
Additive Manufacturing ◽  
Reverse Engineering ◽  
Impact Damage ◽  
Three Dimensional ◽  
Deposition Process ◽  
Material Testing ◽  
Hybrid Process ◽  
Metallic Component ◽  
Three Dimensional Models

Metallic components can gain defects such as dents, cracks, wear, heat checks, deformation, etc., that need to be repaired before reinserting into service for extending the lifespan of these parts. In this study, a hybrid process was developed to integrate reverse engineering, pre-repair processing, additive manufacturing, and material testing for the purpose of part remanufacturing. Worn components with varied defects were scanned using a 3D scanner to recreate the three-dimensional models. Pre-repair processing methods which include pre-repair machining and heat-treatment were introduced. Strategies for pre-repair machining of defects including surface impact damage, surface superficial damage and cracking were presented. Pre-repair heat-treatment procedure for H13 tool steel which was widely used in die/mold application was introduced. Repair volume reconstruction methodology was developed to regain the missing geometry on worn parts. The repair volume provides a geometry that should be restored in the additive manufacturing process. A damaged component was repaired using the directed energy deposition process to rebuild the worn geometry. The repaired part was inspected in microstructure and mechanical aspects to evaluate the repair. The hybrid process solved key issues associated with repair, providing a solution for automated metallic component remanufacturing.

Alternating Force Based Drop-on-Demand Microdroplet Formation and Three-Dimensional Deposition

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Long Zhao ◽  
Karen Chang Yan ◽  
Rui Yao ◽  
Feng Lin ◽  
Wei Sun
Keyword(s):  
Process Parameters ◽  
Droplet Diameter ◽  
Three Dimensional ◽  
Inertial Force ◽  
Deposition Process ◽  
Droplet Formation ◽  
Solution Viscosity ◽  
Cell Printing ◽  
On Demand ◽  
Drop On Demand

Drop-on-demand (DOD) microdroplet formation and deposition play an important role in additive manufacturing, particularly in printing of three-dimensional (3D) in vitro biological models for pharmacological and pathological studies, for tissue engineering and regenerative medicine applications, and for building of cell-integrated microfluidic devices. In development of a DOD based microdroplet deposition process for 3D cell printing, the droplet formation, controlled on-demand deposition and at the single-cell level, and most importantly, maintaining the viability and functionality of the cells during and after the printing are all remaining to be challenged. This report presents our recent study on developing a novel DOD based microdroplet deposition process for 3D printing by utilization of an alternating viscous and inertial force jetting (AVIFJ) mechanism. The results include an analysis of droplet formation mechanism, the system configuration, and experimental study of the effects of process parameters on microdroplet formation. Sodium alginate solutions are used for microdroplet formation and deposition. Key process parameters include actuation signal waveforms, nozzle dimensional features, and solution viscosity. Sizes of formed microdroplets are examined by measuring the droplet diameter and velocity. Results show that by utilizing a nozzle at a 45 μm diameter, the size of the formed microdroplets is in the range of 52–72 μm in diameter and 0.4–2.0 m/s in jetting speed, respectively. Reproducibility of the system is also examined and the results show that the deviation of the formed microdroplet diameter and the droplet deposition accuracy is within 6% and 6.2 μm range, respectively. Experimental results demonstrate a high controllability and precision for the developed DOD microdroplet deposition system with a potential for precise cell printing.

Effects of Substrate Parameters on the Residual Stress and Deflection of Ti-6Al-4V Walls in Additive Manufacturing Process

2020 ◽  
Vol 976 ◽  
pp. 156-161
Author(s):  
Shu Guang Chen ◽  
Yi Du Zhang ◽  
Qiong Wu ◽  
Han Jun Gao
Keyword(s):  
Heat Transfer ◽  
Residual Stress ◽  
Additive Manufacturing ◽  
Three Dimensional ◽  
Element Model ◽  
Length Change ◽  
Deposition Process ◽  
Stress Profile ◽  
Maximum Deflection ◽  
Residual Stress Profile

Given substrate parameters affect the heat transfer during additive manufacturing (AM) deposition process, the precision and residual stress of the component will also be affected. Such effect is an important aspect that should be considered but has not been reported. Thus, this paper presents a three-dimensional thermo-mechanical finite element model to study the effects of substrate parameters on the residual stress of Ti-6Al-4V walls during the AM process. The thermal and deflection histories and residual stress profile with different substrate parameters were investigated. Results show that the influence of the substrate height on the deflection, heat transfer and residual stress is most obvious, the length change has little influence on the deflection and stress distribution. The maximum deflection difference between the heights of 2.4 and 10.4 mm is 92.12%, the maximum deflection is reduced by 39.65% with the width increased from 15.4mm to 35.4mm. And the increased height is beneficial to the uniform of Z component residual stress but decrease uniformity of Y component residual stress.

scholarly journals Additive Manufacturing of Ti6Al4V with Wire Laser Metal Deposition Process

2021 ◽  
Vol 1016 ◽  
pp. 24-29
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Deposition Process ◽  
Travel Speed ◽  
Beam Power ◽  
Feed Speed ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Growth Prospects ◽  
Wire Feed

Additive manufacturing (AM) using wire as an input material is currently in full swing, with very strong growth prospects thanks to the possibility of creating large parts, with high deposition rates, but also a low investment cost compared to the powder bed fusion machines. A versatile 3D printing device using a Direct Energy Deposition Wire-Laser (DED-W Laser) with Precitec Coaxprinter station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters. The geometrical and metallurgical of produced parts are analyzed. In the literature, several authors agree to define wire feed speed, travel speed, and laser beam power as first-order process parameters governing laser-wire deposition. This study shows the relative importance of these parameters taking separately as well as the importance of their sequencing at the start of the process. Titanium deposit are obtained with powers never explored in bibliography (up to 5 kW), and wire feed speed up to 5 m.min-1 with a complete process repeatability.

scholarly journals Modeling and Experimental Study of the Localized Electrochemical Micro Additive Manufacturing Technology Based on the FluidFM

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2783
Author(s):  
Wanfei Ren ◽  
Jinkai Xu ◽  
Zhongxu Lian ◽  
Peng Yu ◽  
Huadong Yu
Keyword(s):  
Additive Manufacturing ◽  
Complex Structure ◽  
Three Dimensional ◽  
Linear Structure ◽  
Deposition Process ◽  
Manufacturing Technology ◽  
Large Area ◽  
Metal Structures ◽  
Additive Manufacturing Technology ◽  
Liquid Feeding

In this work, the localized electrochemical micro additive manufacturing technology based on the FluidFM (fluidic force microscope) has been introduced to fabricate micro three-dimensional overhang metal structures at sub-micron resolution. It breaks through the localized deposition previously achieved by micro-anode precision movement, and the micro-injection of the electrolyte is achieved in a stable electric field distribution. The structure of electrochemical facilities has been designed and optimized. More importantly, the local electrochemical deposition process has been analyzed with positive source diffusion, and the mathematical modeling has been revealed in the particle conversion process. A mathematical model is proposed for the species flux under the action of pulsed pressure in an innovatively localized liquid feeding process. Besides, the linear structure, bulk structure, complex structure, and large-area structure of the additive manufacturing are analyzed separately. The experimental diameter of the deposited cylinder structure is linearly fitted. The aspect ratio of the structure is greater than 20, the surface roughness value is between 0.1–0.2 μm at the surface of bulk structures, and the abilities are verified for deposition of overhang, hollow complex structures. Moreover, this work verifies the feasibility of 3D overhang array submicron structure additive manufacturing, with the application of pulsed pressure. Furthermore, this technology opens new avenues for the direct fabrication of nano circuit interconnection, tiny sensors, and micro antennas.

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