scholarly journals Characterizations of Polymer Gears Fabricated by Differential Pressure Vacuum Casting and Fused Deposition Modeling

Polymers ◽  
2021 ◽  
Vol 13 (23) ◽  
pp. 4126
Author(s):  
Chil-Chyuan Kuo ◽  
Ding-Yang Li ◽  
Zhe-Chi Lin ◽  
Zhong-Fu Kang
Keyword(s):  
Additive Manufacturing ◽  
Weld Line ◽  
Cost Effective ◽  
Low Noise ◽  
Differential Pressure ◽  
Process Conditions ◽  
Fiber Reinforced ◽  
Vacuum Casting ◽  
Fused Deposition ◽  
Silicone Rubber Mold

In recent years, polymer gears have gradually become more widely employed in medium or heavy-duty conditions based on weight reduction in transmission systems because of low costs and low noise compared to metal gears. In the current industry, proposing a cost-effective approach to the manufacture of polymer gears is an important research issue. This paper investigates the wear performance of polymer gears fabricated with eight different kinds of materials using differential pressure vacuum casting and additive manufacturing techniques. It was found that both additive manufacturing and differential pressure vacuum casting seem to be an effective and cost-effective method for low-volume production of polymer gears for industrial applications. The gate number of one is the optimal design to manufacture a silicone rubber mold for differential pressure vacuum casting since the weld line of the polymer is only one. Polyurethane resin, 10 wt.% glass fiber-reinforced polylatic acid (PLA), or 10 wt.% carbon fiber-reinforced PLA are suggested for manufacturing gears for small quantity demand based on the deformation and abrasion weight percentage under process conditions of 3000 rpm for 120 min; epoxy resin is not suitable for making gears because part of the teeth will be broken during abrasion testing.

Material Flow Rate Estimation in Material Extrusion Additive Manufacturing

2021 ◽  
Vol 13 (1) ◽  
pp. 46-56
Author(s):  
G.P. Greeff
Keyword(s):  
Additive Manufacturing ◽  
Flow Rate ◽  
Material Flow ◽  
Fused Deposition Modeling ◽  
Volumetric Flow Rate ◽  
Cost Effective ◽  
Fused Filament Fabrication ◽  
Material Extrusion ◽  
Fused Deposition ◽  
G Code

The additive manufacturing of products promises exciting possibilities. Measurement methodologies, which measure an in-process dataset of these products and interpret the results, are essential. However, before developing such a level of quality assurance several in-process measurands must be realized. One of these is the material flow rate, or rate of adding material during the additive manufacturing process. Yet, measuring this rate directly in material extrusion additive manufacturing presents challenges. This work presents two indirect methods to estimate the volumetric flow rate at the liquefier exit in material extrusion, specifically in Fused Deposition Modeling or Fused Filament Fabrication. The methods are cost effective and may be applied in future sensor integration. The first method is an optical filament feed rate and width measurement and the second is based on the liquefier pressure. Both are used to indirectly estimate the volumetric flow rate. The work also includes a description of linking the G-code command to the final print result, which may be used to create a per extrusion command model of the part.

scholarly journals Characterization and Optimization of Mechanical Properties of ABS Parts Manufactured by the Fused Deposition Modelling Process

2014 ◽  
Vol 2014 ◽  
pp. 1-13 ◽  
Author(s):  
Godfrey C. Onwubolu ◽  
Farzad Rayegani
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Group Method ◽  
Fused Deposition Modelling ◽  
Process Conditions ◽  
Research Issues ◽  
Practical Applications ◽  
Fused Deposition ◽  
Study Results

While fused deposition modelling (FDM) is one of the most used additive manufacturing (AM) techniques today due to its ability to manufacture very complex geometries, the major research issues have been to balance ability to produce aesthetically appealing looking products with functionality. In this study, five important process parameters such as layer thickness, part orientation, raster angle, raster width, and air gap have been considered to study their effects on tensile strength of test specimen, using design of experiment (DOE). Using group method of data handling (GMDH), mathematical models relating the response with the process parameters have been developed. Using differential evolution (DE), optimal process parameters have been found to achieve good strength simultaneously for the response. The optimization of the mathematical model realized results in maximized tensile strength. Consequently, the additive manufacturing part produced is improved by optimizing the process parameters. The predicted models obtained show good correlation with the measured values and can be used to generalize prediction for process conditions outside the current study. Results obtained are very promising and hence the approach presented in this paper has practical applications for design and manufacture of parts using additive manufacturing technologies.

scholarly journals Comparison of different additive manufacturing patterns on the performance of rapid vacuum casting for mating parts via the Taguchi method

2020 ◽  
Vol 14 (1) ◽  
pp. 6417-6429 ◽  
Author(s):  
Nur Nabilah Mohd Mustafa ◽  
Aini Zuhra Abdul Kadir ◽  
N. H. Akhmal Ngadiman ◽  
A. Ma'aram ◽  
K. Zakaria
Keyword(s):  
Additive Manufacturing ◽  
Taguchi Method ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Vacuum Casting ◽  
Fused Deposition ◽  
Small Series ◽  
Master Pattern

Rapid vacuum casting has been proven to be a successful method in producing high-quality parts in small series. However, a challenge lies in the selection of proper Additive Manufacturing (AM) technologies for the development of a master pattern for the vacuum casting process. Each AM technologies differ from one another in terms of dimensional accuracy, surface finish, cost and lead times. The aim of this study is to investigate the performance of casting mating parts based on different additive manufacturing patterns for small batch. Three types of AM-based patterns: Fused Deposition Modeling (FDM), Stereolithography (SLA) and Multi-Jet Fusion (MJF) were compared. The Taguchi method, Signal to Noise ratio (S/N), Analysis of Variance (ANOVA) and T-test were conducted in determining the optimized parameters. From the findings, curing time is shown to be a significant parameter for dimensional accuracy and surface finish. Dimensional deviation varies in different directions of parts. For surface finish, there was only a slight change from the master pattern whereas the surface roughness of casting parts decreased within the range 0.23% to 2.85%. Tolerance grades for the selected dimensions of the parts were in the permissible range, based on ISO286-1:2010. When using distinct kinds of AM patterns to create replacement components, design tolerance is needed. It was suggested to select AM technology similar to that had been used for the original components.  Battery cover was selected as a case study to represent the mating application parts.

Property Enhancement of Carbon Fiber-Reinforced Polylactic Acid Composites Prepared by Fused-Deposition Modeling

2020 ◽  
pp. 455-478
Author(s):  
Pravin R. Kubade ◽  
Hrushikesh B. Kulkarni ◽  
Vinayak C. Gavali
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Fiber Reinforced ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Properties Of Composites

Additive Manufacturing or three-dimensional printing refers to a process of building lighter, stronger three-dimensional parts, manufactured layer by layer. Additive manufacturing uses a computer and CAD software which passes the program to the printer to build the desired shape. Metals, thermoplastic polymers, and ceramics are the preferred materials used for additive manufacturing. Fused deposition modeling is one additive manufacturing technique involving the use of thermoplastic polymer for creating desired shape. Carbon fibers can be added into polymer to strengthen the composite without adding additional weight. Present work deals with the manufacturing of Carbon fiber-reinforced Polylactic Acid composites prepared using fused deposition modeling. Mechanical and thermo-mechanical properties of composites are studied as per ASTM standards and using sophisticated instruments. It is observed that there is enhancement in thermo-mechanical properties of composites due to addition reinforcement which is discussed in detail.

Effects of Process Variables on Extrusion of Carbon Fiber Reinforced ABS Filament for Additive Manufacturing

2015 ◽  
Author(s):  
Emmett Hull ◽  
Weston Grove ◽  
Meng Zhang ◽  
Xiaoxu Song ◽  
Z. J. Pei ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Layer By Layer ◽  
Fiber Reinforced ◽  
Process Variables ◽  
Fused Deposition ◽  
3D Printers ◽  
Carbon Fiber Reinforced

Additive manufacturing (3D printing) is a class of manufacturing processes where material is deposited in a layer-by-layer fashion to fabricate a three-dimensional part directly from a computer-aided design (CAD) model. With a current market share of 44%, thermoplastic-based additive manufacturing such as fused deposition modeling (FDM) is a prevailing technology. A preliminary extrusion process is required to produce thermoplastic filaments for use in FDM 3D printers. It is crucial that extruded filament must have constant dimensional accuracy for FDM 3D printers to produce the desired object with precision. In this study, carbon fibers were blended with acrylonitrile butadiene styrene (ABS) thermoplastics to produce carbon fiber reinforced ABS filaments in order to improve the mechanical properties of FDM-printed objects. During filament extrusion, three process variables showed significant effects on filament diameter, expansion percentage, and extrusion rate. These process variables included carbon fiber content, extrusion temperature, and nozzle size. The objective of this study is to test the feasible ranges of these process variables and to investigate their effects on filament extrusion. Results of this study will provide knowledge on quality improvement of carbon fiber reinforced ABS filament extrusion for additive manufacturing.

CHEMICAL PULPING. Oxidative degradation of AOX in softwood-based kraft mill effluents from E C F bleachin g

2012 ◽  
Vol 27 (4) ◽  
pp. 707-713 ◽  
Author(s):  
Jukka Pekka lsoaho ◽  
Suvi Tarkkanen ◽  
Raimo Alen ◽  
Juha Fiskari
Keyword(s):  
Reaction Time ◽  
Oxidative Degradation ◽  
Cost Effective ◽  
Process Conditions ◽  
Main Process ◽  
Chemical Pulping ◽  
Kraft Mill ◽  
Organic Halogens ◽  
Aox Removal ◽  
Adsorbable Organic Halogens

Abstract Softwood-based kraft mill bleaching effluents from the initial bleaching stages D0 and E1 (the bleaching sequence being D0E 1D 1 E2D2) were treated by the oxidative Fenton method (H20rFeS04) to decompose organic pollutants contammg adsorbable organic halogens (AOX). Experiments designed using the Taguchi method were applied to predict the process conditions that would result in a cost-effective and adequate removal of AOX. In addition to the composition and concentration of the reagents (H202 and Fe2+), the main process parameters selected were temperature and reaction time, while pH was adj usted to an approximate value of 4 (the volumetric ratio of the mixed effluents D0:E 1 was 3 :2). The results indicated that an AOX removal of about 70% for this mixture ( corresponding to about 50% for the mill) was achieved when the eftluent samples were treated for 60 min at 70°C with H202 and Fe2+ at a concentration of 1 600 mg/1 and 28 mg/1, respectively.

scholarly journals Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Polymers ◽  
2021 ◽  
Vol 13 (8) ◽  
pp. 1224
Author(s):  
Chil-Chyuan Kuo ◽  
Wei-Hua Chen
Keyword(s):  
Thermal Conductivity ◽  
Injection Molding ◽  
Cooling Time ◽  
Performance Ratio ◽  
Cooling Efficiency ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Fused Deposition ◽  
Silicone Rubber Mold

Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

Evaluation of cost-effective hybrid fiber reinforced ECC

Sadhana ◽  
2021 ◽  
Vol 46 (2) ◽  
Author(s):  
Maninder Singh ◽  
Babita Saini ◽  
HD Chalak
Keyword(s):  
Cost Effective ◽  
Fiber Reinforced ◽  
Hybrid Fiber
Sign in / Sign up

Export Citation Format

Share Document