Optimized Design of Structural Components Realized Through Additive Manufacturing

2015 ◽  
Author(s):  
Stefano Baglioni ◽  
Claudio Braccesi ◽  
Filippo Cianetti ◽  
Paolo Conti ◽  
Gianluca Rossi
Keyword(s):  
Additive Manufacturing ◽  
Stress Field ◽  
Optimization Technique ◽  
Field Application ◽  
Production Costs ◽  
Raw Material ◽  
Test Case ◽  
Optimized Design ◽  
Material Distribution ◽  
Specific Test

Nowadays Additive Manufacturing (AM) is going through a very fast development, spreading in many different mechanical contexts. The main advantages of this technology are: production costs reduction (prototype realization time reduction, raw material consumption reduction, almost zero manpower needed...), significant reliability (compared to the standard production process) and last but not least extreme freedom in product shape design. The last characteristic makes it possible to adopt new design approach focusing on component shape and material distribution optimization; a new design paradigm must be developed to fully take advantage of these opportunities: the designer can develop new concepts with very complex shapes and sophisticated topological solution owing to opportunities yielded by AM with in mind only the week limitations given by this technology. In detail this work aims to highlight a new design strategy that consist of a combination of structural optimization tools (Topology Optimization TO) and non-contact stress field measurement technique (based on thermo-elasticity). The goal is to develop an iterative design procedures which links the design shape optimization with the experimental stress evaluation, allowing a wise material distribution in order to enhance the resistance. The idea is to accomplish an initial designing phase, letting the designer free to define a first rough design concept taking into account the information provided by the TO to exploit the material in the best way. Then, the concept must be verified in both: model numerical F.E.M. analysis and prototype experimental evaluation of the stress field. Eventually, according to the verification analysis results, the model will be modified to reach the desired requirements in terms of allowed deformation, stress resistance and fatigue life. The paper will display the optimization technique iterative process (based on Solid Isotropic Material with Penalization – SIMP – scheme) in a general way and through a practical example. As a reference, this methodology has been applied to a specific test case in order to design and optimize a new concept of a structural mechanical component of a mountain bike. The component was, first realized as a prototype in thermoplastic material and finally designed to be realized in metal for in field application.

An Interactive Manufacturability Analysis and Tolerance Allocation Tool for Additive Manufacturing

2018 ◽  
Author(s):  
Hannah D. Budinoff ◽  
Sara McMains ◽  
Alberto Rinaldi
Keyword(s):  
Additive Manufacturing ◽  
Tolerance Allocation ◽  
Production Costs ◽  
Programming Approach ◽  
Test Case ◽  
Tolerance Limits ◽  
Specific Knowledge ◽  
Geometric Tolerances ◽  
The Cost ◽  
Single Orientation

Geometric tolerances for new products are sometimes assigned without specific knowledge of the cost or feasibility of manufacturing them to the assigned tolerances, which can significantly drive up production costs and lead to delays and design revisions. We present an interactive tool that quickly estimates the manufacturability of assigned tolerances for additive manufacturing and a compact visualization to present this information to the designer. The designer can use the system to explore feasible build orientations and then adjust specified tolerance limits if all tolerances are not simultaneously achievable at a single orientation. After the designer is satisfied that the range of feasible orientations has been fully explored, a physical programming approach is used to identify a single orientation to best satisfy the designer’s preferences. The calculation and visualization of the results is done in real-time, enabling quick iteration. A test case is presented to illustrate the use of the tool.

Graubündens Wald im Fokus | Focus on the Grisons forest

2009 ◽  
Vol 160 (7) ◽  
pp. 195-200
Author(s):  
Reto Hefti
Keyword(s):  
Climate Change ◽  
Global Warming ◽  
Natural Hazards ◽  
Positive Attitude ◽  
Production Costs ◽  
Raw Material ◽  
Intensive Use ◽  
Form Part ◽  
New Challenges ◽  
The Government

In the mountainous canton Grisons, much visited by tourists, the forest has always had an important role to play. New challenges are now presenting themselves. The article goes more closely into two themes on the Grisons forestry agenda dominating in the next few years: the increased use of timber and climate change. With the increased demand for logs and the new sawmill in Domat/Ems new opportunities are offered to the canton for more intensive use of the raw material, wood. This depends on a reduction in production costs and a positive attitude of the population towards the greater use of wood. A series of measures from the Grisons Forestry Department should be of help here. The risk of damage to infrastructure is particularly high in a mountainous canton. The cantonal government of the Grisons has commissioned the Forestry Department to define the situation concerning the possible consequences of global warming on natural hazards and to propose measures which may be taken. The setting up of extensive measurement and information systems, the elaboration of intervention maps, the estimation of the danger potential in exposed areas outside the building zone and the maintenance of existing protective constructions through the creation of a protective constructions register, all form part of the government programme for 2009 to 2012. In the Grisons, forest owners and visitors will have to become accustomed to the fact that their forests must again produce more wood and that, on account of global warming, protective forests will become even more important than they already are today.

SELISIH BIAYA PRODUKSI SEBAGAI ALAT PENGENDALIAN MANAJEMEN PT INDO PUSAKA BERAU

2019 ◽  
Vol 3 (02) ◽  
pp. 397
Author(s):  
SAFITRI NURHIDAYATI ◽  
RIZKI AMELYA SYAM
Keyword(s):  
Raw Materials ◽  
Field Research ◽  
Analytical Tool ◽  
Production Costs ◽  
Raw Material ◽  
Labor Costs ◽  
Material Costs ◽  
Library Research ◽  
The Difference ◽  
The Cost

This study aims to analyze whether the difference that occurs in the cost of raw materials, direct labor, and factory overhead costs between the standard costs and the actual costs in PLTU LATI is a difference that is favorable or unfavorable. Data collection techniques with field research and library research. The analytical tool used is the analysis of the difference in raw material costs, the difference in direct labor costs and the difference in factory overhead costs. The hypothesis in this study is that the difference allegedly occurs in the cost of raw materials, direct labor costs, and factory overhead costs at PT Indo Pusaka Berau Tanjung Redeb is a favorable difference. The results showed that the difference in the cost of producing MWh electricity at PT Indo Pusaka Berau Tanjung Redeb in 2018, namely the difference in the price of raw material costs Rp. 548,029.80, - is favorable, the difference in quantity of raw materials is Rp. 957,216,602, - is (favorable) , the difference in direct labor costs Rp 2,602,642,084, - is (unfavorable), and the difference in factory overhead costs Rp 8,807,051,422, - is (favorable) This shows that the difference in the overall production cost budget is favorable or profitable. This beneficial difference shows that the company is really able to reduce production costs optimally in 2018.  

Technical accounting: sugar extraction and losses

2020 ◽  
pp. 712-721
Author(s):  
Jan Maarten de Bruijn de Bruijn
Keyword(s):  
Process Improvement ◽  
Best Practice ◽  
Continuous Process ◽  
Extraction Yield ◽  
Production Costs ◽  
Raw Material ◽  
Sugar Production ◽  
Cost Leadership ◽  
Sugar Extraction ◽  
White Sugar

The bought sugar in the processed raw material (either beet or cane) comprises a high financial value and may contribute to somewhere around 50% of the white sugar production costs. It is therefore of the utmost importance to minimize sugar losses along the process and produce as much white sugar as possible from the raw material. This paper explains the principle of technical accounting as tool to control sugar extraction and losses in beet sugar manufacture. The sugar mass balance used to calculate the overall sugar extraction yield, as well as several simple calculations proposed for estimating the different sugar losses (like e.g. extraction (diffusion) losses, infection losses, sugar losses in molasses, etc.) in the subsequent process steps will be explained in detail. Proper technical accounting is considered indispensable for continuous process control and process improvement in pursuit of best-practice operation and cost-leadership.

scholarly journals VOLCO-X: numerical simulation of material distribution and voids in extrusion additive manufacturing

2021 ◽  
pp. 101900
Author(s):  
Rafael Quelho de Macedo ◽  
Rafael Thiago Luiz Ferreira ◽  
Andrew Gleadall ◽  
Ian Ashcroft
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Material Distribution

scholarly journals Rheological behavior of high consistency enzymatically fibrillated cellulose suspensions

Cellulose ◽  
2021 ◽  
Author(s):  
Aayush Kumar Jaiswal ◽  
Vinay Kumar ◽  
Alexey Khakalo ◽  
Panu Lahtinen ◽  
Katariina Solin ◽  
...  
Keyword(s):  
Power Law ◽  
Shear Viscosity ◽  
Production Costs ◽  
Raw Material ◽  
Structure Property ◽  
Morphological Examination ◽  
Direct Function ◽  
Typical Application ◽  
Enzyme Dosage ◽  
High Consistency

AbstractHigh-consistency processing of fibrillated cellulose materials is attractive for commercial applications due to potential for lowered production costs, energy savings and easier logistics. The current work investigated structure–property relationships of fibrillated cellulose suspensions produced at 20% consistency using VTT HefCel (High-consistency enzymatic fibrillation of cellulose) technology. Morphological examination of the fibrillated materials revealed that enzymatic action on the cellulose substrates was not a direct function of enzyme dosage but rather was dependent on the raw material composition. Furthermore, shear viscosity of the HefCel suspensions was found to decrease with increasing enzyme dosage while the water retention increased. The shear viscosity followed power law relationship with the power law index varying in the range 0.11–0.73. The shear-thinning behavior decreased with increasing consistency. Moreover, suspension viscosity ($$\upmu$$ μ ) was found to be highly dependent on the consistency ($$\mathrm{c})$$ c ) as $$\upmu \sim {\mathrm{c}}^{\mathrm{m}}$$ μ ∼ c m , with $$\mathrm{m}$$ m ranging from 2.75 to 4.31 for different samples. Yield stress (τy) of the HefCel suspensions was measured at 7 and 10% consistencies. The performance of the fibrillated cellulose grades in a typical application was demonstrated by casting films, which were characterized for their mechanical properties. Graphic abstract

scholarly journals Economic and Sustainability of Biodiesel Production—A Systematic Literature Review

2021 ◽  
Vol 3 (1) ◽  
pp. 19-36
Author(s):  
Tamás Mizik ◽  
Gábor Gyarmati
Keyword(s):  
Literature Review ◽  
Systematic Literature Review ◽  
Volatile Fatty Acids ◽  
First Generation ◽  
Production Costs ◽  
Raw Material ◽  
Biodiesel Production ◽  
Important Research Topic ◽  
The Social ◽  
High Production

As Earth’s fossil energy resources are limited, there is a growing need for renewable resources such as biodiesel. That is the reason why the social, economic and environmental impacts of biofuels became an important research topic in the last decade. Depleted stocks of crude oil and the significant level of environmental pollution encourage researchers and professionals to seek and find solutions. The study aims to analyze the economic and sustainability issues of biodiesel production by a systematic literature review. During this process, 53 relevant studies were analyzed out of 13,069 identified articles. Every study agrees that there are several concerns about the first-generation technology; however, further generations cannot be price-competitive at this moment due to the immature technology and high production costs. However, there are promising alternatives, such as wastewater-based microalgae with up to 70% oil content, fat, oils and grease (FOG), when production cost is below 799 USD/gallon, and municipal solid waste-volatile fatty acids technology, where the raw material is free. Proper management of the co-products (mainly glycerol) is essential, especially at the currently low petroleum prices (0.29 USD/L), which can only be handled by the biorefineries. Sustainability is sometimes translated as cost efficiency, but the complex interpretation is becoming more common. Common elements of sustainability are environmental and social, as well as economic, issues.

scholarly journals Wire Arc Additive Manufacturing: Review on Recent Findings and Challenges in Industrial Applications and Materials Characterization

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 939
Author(s):  
Mukti Chaturvedi ◽  
Elena Scutelnicu ◽  
Carmen Catalina Rusu ◽  
Luigi Renato Mistodie ◽  
Danut Mihailescu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Structural Integrity ◽  
Industrial Applications ◽  
Raw Material ◽  
Continuous Increase ◽  
Control Optimization ◽  
Modern Manufacturing ◽  
Directed Energy ◽  
Manufacturing Technologies ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a fusion manufacturing process in which the heat energy of an electric arc is employed for melting the electrodes and depositing material layers for wall formation or for simultaneously cladding two materials in order to form a composite structure. This directed energy deposition-arc (DED-arc) method is advantageous and efficient as it produces large parts with structural integrity due to the high deposition rates, reduced wastage of raw material, and low consumption of energy in comparison with the conventional joining processes and other additive manufacturing technologies. These features have resulted in a constant and continuous increase in interest in this modern manufacturing technique which demands further studies to promote new industrial applications. The high demand for WAAM in aerospace, automobile, nuclear, moulds, and dies industries demonstrates compatibility and reflects comprehensiveness. This paper presents a comprehensive review on the evolution, development, and state of the art of WAAM for non-ferrous materials. Key research observations and inferences from the literature reports regarding the WAAM applications, methods employed, process parameter control, optimization and process limitations, as well as mechanical and metallurgical behavior of materials have been analyzed and synthetically discussed in this paper. Information concerning constraints and enhancements of the wire arc additive manufacturing processes to be considered in terms of wider industrial applicability is also presented in the last part of this paper.

Numerical Simulation of Filling and Solidification in Sand Casting by Procast

2013 ◽  
Vol 791-793 ◽  
pp. 550-553 ◽  
Author(s):  
Dong Dong Han ◽  
Cheng Jun Wang ◽  
Juan Chang ◽  
Lei Chen ◽  
Huai Bei Xie
Keyword(s):  
Numerical Simulation ◽  
Heat Dissipation ◽  
Solidification Process ◽  
Simulation Software ◽  
Sand Casting ◽  
Production Costs ◽  
Raw Material ◽  
Casting Defects ◽  
Three Dimension ◽  
Filling And Solidification

At present, pulley produced in China has been able to meet the demand of domestic and international markets. But there are many problem of the pulley industry in our country, such as too many production enterprises and the low level of export products. And as components of drive system are light weight and raw material price of pulley casting are rising, manufacturing requirements of the pulley are also more and more high. Aiming at the casting defects of pulley that enterprise current product, pulley casting blank model of common material HT250 be made by three-dimension software, numerical simulation of filling and solidification process for pulley sand casting by the casting simulation software Procast, the size and location of the various casting defects were forecasted and analyzed, reflecting the pulley filling and solidification process of the actual situation, due to the thicker pulley rim and less heat dissipation, position of shrinkage is close to the middle of rim [, a method of eliminating defects is proposed to realize sequential solidification, and thus to minimize porosity shrinkage and improve casting performance and reduce casting time and reduce production costs.

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