Effect of 3D Printing Parameters on the Refractive Index, Attenuation Coefficient, and Birefringence of Plastics in Terahertz Range

The refractive indices, attenuation coefficients, and level of birefringence of various 3D printing plastics may change depending on the printing parameters. Transmission terahertz time-domain spectroscopy was used to look for such effects in Copolyester (CPE), Nylon, Polycarbonate (PC), Polylactic acid, and Polypropylene. The thickness of each sample was measured using an external reference structure and time-of-flight measurements. The parameters varied were printer nozzle size, print layer height, and print orientation. Comparison of these parameters showed that a printer’s nozzle size and print layer height caused no change in real refractive index or attenuation coefficient. A change in printing orientation from vertical to horizontal caused an increase both in real refractive index and in attenuation coefficient. In vertically printed samples, the increase in birefringence was proportional to the increase in layer height and inversely proportional to nozzle size. There was no measurable intrinsic birefringence in the horizontally printed samples. These effects should be taken into account in the design of FDM 3D printed structures that demand tailored refractive indices and attenuation coefficients, while also providing a foundation for nondestructive evaluation of FDM 3D printed objects and structures.

Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Three-dimensional (3D) printing is one of the significant industrial manufacturing methods in the modern era. Many materials are used for 3D printing; however, as the most used material in fused deposition modelling (FDM) technology, acrylonitrile butadiene styrene (ABS) offers good mechanical properties. It is perfect for making structures for industrial applications in complex environments. Three-dimensional printing parameters, including building orientation, layers thickness, and nozzle size, critically affect the crack growth in FDM structures under complex loads. Therefore, this paper used the dynamic bending vibration test to investigate their influence on fatigue crack growth (FCG) rate under dynamic loads and the Paris power law constant C and m. The paper proposed an analytical solution to determine the stress intensity factor (SIF) at the crack tip based on the measurement of structural dynamic response. The experimental results show that the lower ambient temperature, as well as increased nozzle size and layer thickness, provide a lower FCG rate. The printing orientation, which is the same as loading, also slows the crack growth. The linear regression between these parameters and Paris Law’s coefficient also proves the same conclusion.

Influence of span-wise coherence on the acoustic radiation in a cylinder wake

The aim of this study is to detect and visualise the influence of span-wise coherence on propagating sound waves emanating from a flow around circular cylinders with span-wise variations of the local radius. Synchronous particle image velocimetry (PIV) and microphone measurements are performed in a circular wind tunnel with a nozzle size of 0.4 m×0.4 m at a maximum flow speed of U∞ = 43m s−1 . The test section is surrounded by a full anechoic chamber of approximately 9 m×9 m×5 m.

Effects of Printing Parameters on the Fatigue Behaviour of 3D-Printed ABS under Dynamic Thermo-Mechanical Loads

Fused deposition modelling (FDM) is the most widely used additive manufacturing process in customised and low-volume production industries due to its safe, fast, effective operation, freedom of customisation, and cost-effectiveness. Many different thermoplastic polymer materials are used in FDM. Acrylonitrile butadiene styrene (ABS) is one of the most commonly used plastics owing to its low cost, high strength and temperature resistance. The fabricated FDM ABS parts commonly work under thermo-mechanical loads in actual practice. For producing FDM ABS components that show high fatigue performance, the 3D printing parameters must be effectively optimized. Hence, this study evaluated the bending fatigue performance for FDM ABS beams under different thermo-mechanical loading conditions with varying printing parameters, including building orientations, nozzle size, and layer thickness. The combination of three building orientations (0°, ±45°, and 90°), three nozzle sizes (0.4, 0.6, and 0.8 mm) and three-layer thicknesses (0.05, 0.1, and 0.15 mm) were tested at different environmental temperatures ranging from 50 to 70 °C. The study attempted to find the optimal combination of the printing parameters to achieve the best fatigue behaviour of the FDM ABS specimen. The experiential results showed that the specimen with 0° building orientation, 0.8 mm filament width, and 0.15 mm layer thickness vibrated for the longest time before the fracture at each temperature. Both a larger nozzle size and thicker layer height can increase the fatigue life. It was concluded that printing defects significantly decreased the fatigue life of the 3D-printed ABS beam.

Alternative Nozzle Reinforcement Rules for Gasketed Plate Heat Exchangers

This paper aims to provide an alternative design approach to the current nozzle reinforcement rules for gasketed plate heat exchangers (GPHE) designed in accordance with Appendix 45 of ASME BPVC Section VIII, Div. 1. The current ASME BPVC Section VIII, Div. 1 nozzle reinforcement rules require the use of bending stress calculated at the center of the GPHE end plate where the bending stress has the highest value. Typical GPHE’s have inlet and outlet nozzles located near the top or bottom of the GPHE end plates where the bending stresses are lower as compared to the bending stresses at the center of the plates. For nozzle reinforcement analysis in GPHE end plates, this alternative design approach suggests utilizing the bending stress values calculated in vicinity of nozzles in lieu of bending stress value at center of the end plate. It also suggests utilizing the modified UG-39 rules for GPHE end plate nozzle reinforcement. In order to optimize the design thickness of the GPHE end plates, this paper will analyze the impact of nozzle size and location on bending stresses in the end plates, propose modification of UG-39 rules for GPHE end plates, and to define the limits of the design approach.

Predicting Surface Roughness And Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

The machining of composite materials is difficult because of their non-homogenous structure and their constituents commonly possess a high resistance to cutting. Abrasive waterjet machining (AWJM) is more attractive for composite substrates than conventional machining techniques because of its ability to rapidly machine a wide variety of materials with low reactionary forces on the workpiece, and without creating a heat-affected zone. However, AWJM is prone to producing variable surface roughness and delamination. This dissertation aimed to model these surface roughness and delamination mechanisms. The thesis presents 2D and 3D roughness models capable of predicting the surface roughness during abrasive waterjet (AWJ) trimming of composite substrates. The models were able to predict the measured surface roughness with an average error of 10% and 16%, for the 2D and 3D models, respectively. The thesis also presents experimental and numerical results characterizing the delamination when AWJ piercing and cutting a carbon-fiber/epoxy laminate. Fluid-structure interaction (FSI) models created to simulate the piercing process showed that interlaminar delamination was due to the hydraulic shock (‘water hammer’) associated with liquid jet impact. As expected, increased pressure and nozzle size resulted in ply debonding, and was experimentally verified using 3D x-ray micro-tomography. The composite anisotropy was found to produce an asymmetric shock loading along the liquid-solid interface, which contributed to the asymmetric delamination. The FSI model showed that delamination when cutting carbon-fiber/epoxy depended primarily on the normal interlaminar stress, with relatively large damage zones occurring ahead of the cutting front. This trend was also observed in x-ray micro-tomographs of an AWJ cut. The amount of delamination across different process parameters was also measured using a moisture uptake methodology, and showed that increase traverse speed, increased nozzle size, and decreased abrasive flow rate, increased delamination. Prediction and characterization of surface roughness and delamination when AWJM will allow further improvement of cut-surface finish and structural integrity of composite materials, respectively

Predicting Surface Roughness And Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

The machining of composite materials is difficult because of their non-homogenous structure and their constituents commonly possess a high resistance to cutting. Abrasive waterjet machining (AWJM) is more attractive for composite substrates than conventional machining techniques because of its ability to rapidly machine a wide variety of materials with low reactionary forces on the workpiece, and without creating a heat-affected zone. However, AWJM is prone to producing variable surface roughness and delamination. This dissertation aimed to model these surface roughness and delamination mechanisms. The thesis presents 2D and 3D roughness models capable of predicting the surface roughness during abrasive waterjet (AWJ) trimming of composite substrates. The models were able to predict the measured surface roughness with an average error of 10% and 16%, for the 2D and 3D models, respectively. The thesis also presents experimental and numerical results characterizing the delamination when AWJ piercing and cutting a carbon-fiber/epoxy laminate. Fluid-structure interaction (FSI) models created to simulate the piercing process showed that interlaminar delamination was due to the hydraulic shock (‘water hammer’) associated with liquid jet impact. As expected, increased pressure and nozzle size resulted in ply debonding, and was experimentally verified using 3D x-ray micro-tomography. The composite anisotropy was found to produce an asymmetric shock loading along the liquid-solid interface, which contributed to the asymmetric delamination. The FSI model showed that delamination when cutting carbon-fiber/epoxy depended primarily on the normal interlaminar stress, with relatively large damage zones occurring ahead of the cutting front. This trend was also observed in x-ray micro-tomographs of an AWJ cut. The amount of delamination across different process parameters was also measured using a moisture uptake methodology, and showed that increase traverse speed, increased nozzle size, and decreased abrasive flow rate, increased delamination. Prediction and characterization of surface roughness and delamination when AWJM will allow further improvement of cut-surface finish and structural integrity of composite materials, respectively

Spray Coverage and Biological Efficacy of Single, Twin Symmetrical, and Twin Asymmetrical Flat Fan Nozzles

Proper selection of nozzle type and spray volume is essential to optimize herbicide dose, reducing its adverse environmental effects. It has not been sufficiently evaluated which nozzle type (twin symmetrical flat fan nozzle or the twin asymmetrical one) is more efficient and whether pinoxaden application is more efficient at a low or high spray volume. The spray coverage of a single, twin symmetrical, and twin asymmetrical flat fan nozzles, each in the sizes of 110015, 11002, 110025, 11003, 11004, and 11005 on the moisture-sensitive papers (MSPs) was investigated. The biological efficacy of treatments using pinoxaden against wild oat was investigated. Unlike other nozzle types, the single flat fan nozzle could not cover MSP placed vertically behind the nozzle trajectory. Except for the latter, each nozzle type could cover the MSPs more efficiently with increase in nozzle size. Generally, the nozzles’ performance was twin symmetrical > single = twin asymmetrical flat fan nozzles. A larger nozzle size improved the coverage of MSPs but increased the effective dose (ED50; dose that gives a 50% reduction in dry weight), indicating a decrease in the efficacy of pinoxaden. Among all treatments, the lowest ED50 value was obtained by the twin symmetrical flat fan nozzle 110015 (5.2 g a.i. ha−1). The smaller, more concentrated droplets are required to achieve optimal pinoxaden efficacy against wild oat, which can be provided by a twin symmetrical flat fan nozzle with a smaller size.

Numerical investigation of injection parameters and piston bowl geometries on emission and thermal performance of DI diesel engine

Tightening noose on engine emission norms compelled manufacturers globally to design engines with low emission specially NOx and soot without compromising their performance. Amongst various parameters, shape of piston bowls, injection pressure and nozzle diameter are known to have significant influence over the thermal performance and emission emanating from the engine. This paper investigates the combined effect of fuel injection parameters such as pressure at which fuel is injected and the injection nozzle size along with shape of piston bowl on engine emission and performance. Numerical simulation is carried out using one cylinder naturally aspirated diesel engine using AVL FIRE commercial code. Three geometries of piston bowls with different tumble and swirl characteristics are considered while maintaining the volume of piston bowl, compression ratio, engine speed and fuel injected mass constant along with equal number of variations for injection nozzle size and pressures for this analysis. The investigation corroborates that high swirl and large turbulence kinetic energy (TKE) are crucial for better combustion. TKE and equivalence ratio also increased as the injection pressure increases during the injection period, hence, enhances combustion and reduces soot formation. Increase in nozzle diameter produces higher TKE and equivalence ratio, while CO and soot emission are found to be decreasing and NOx formation to be increasing. Further, optimization is carried out for twenty-seven cases created by combining fuel injection parameters and piston bowl geometries. The case D2H1P1 (H1 = 0.2 mm, P1 = 200 bar) found to be an optimum case because of its lowest emission level with slightly better performance.