Design, finite element analysis (FEA), and fabrication of custom titanium alloy cranial implant using electron beam melting additive manufacturing

Ti6Al4V specimens with porous structures can be fabricated by additive manufacturing to obtain the desired Young’s modulus. Their mechanical strength and deformation behavior can be evaluated using finite element analysis (FEA), with various models and simulation methodologies described in the existing literature. Most studies focused on the evaluation accuracy of the mechanical strength and deformation behavior using complex models. This study presents a simple elastic model for brittle specimens followed by an electron beam additive manufacturing (EBAM) process to predict the initial crack site and threshold of applied stress related to the failure of cubic unit lattice structures. Six cubic lattice specimens with different porosities were fabricated by EBAM, and compression tests were performed and compared to the FEA results. In this study, two different types of deformation behavior were observed in the specimens with low and high porosities. The adopted elastic model and the threshold of applied stress calculated via FEA showed good capabilities for predicting the initial crack sites of these specimens. The methodology presented in this study should provide a simple yet accurate method to predict the fracture initiation of porous structure parts.

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Comparing the Performance of the Biathlon Rifles with Wooden and Titanium Frames

Proceedings ◽

10.3390/proceedings2020049062 ◽

2020 ◽

Vol 49 (1) ◽

pp. 62

Author(s):

Andrey Koptyug ◽

Mikael Bäckström ◽

Victor Olsson

Keyword(s):

Mechanical Properties ◽

Finite Element Analysis ◽

Finite Element ◽

Titanium Alloy ◽

Additive Manufacturing ◽

High Capacity ◽

Mems Sensors ◽

Element Analysis ◽

Design Elements ◽

Manufacturing Technologies

The present paper describes preliminary results of studies carried out using a new measurement setup and a biathlon rifle with two different interchangeable stocks: a commercial, mainly wooden one and one additively manufactured from titanium alloy and a polymer PA 2200, employing lightweight, 3D lattice architecture. A finite element analysis of the predicted mechanical properties of new design elements was carried out prior to the manufacturing. Experiments were carried out using a novel setup for the assessment of athlete and rifle performance in biathlon shooting. Data acquisition was carried out at the rates of few kilosamples per second, using a combination of an airbag-based rifle butt pressure sensor, a trigger loading sensor, strap load cell, and two tri-axis MEMS sensors—an accelerometer and a gyroscope. All tests indicate that a rifle stock additively manufactured from titanium alloy could provide better recoil damping compared to the commercial, mainly wooden one. Together with the high capacity of additive manufacturing technologies in equipment individualization, this may provide additional possibilities for the improvement of sports rifle construction and help athletes achieve better results in competitions.

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