Experimental Investigation of Process Parameters of Al-SiC-B4C MMCs Finished by a Novel Magnetic Abrasive Flow Machining Setup

Abrasive flow machining (AFM) is one of the non-conventional finishing processes used to attain good surface quality and high material removal. However, limited attempts have been made to improve the performance of these processes. This paper presents a novel magnetic abrasive flow machining (MAFM) setup fabricated by adding a magnetization effect in which a nylon fixture and permanent magnets are replaced by a newly fabricated aluminium fixture and coil-type magnets, respectively. Inner cylindrical surfaces of hybrid Al/SiC/B4C metal matrix composites (MMCs) are finished by the MAFM process. One variable at a time (OVAT) approach is used for studying the effect of 6 input parameters, extrusion pressure (Ep), the number of cycles (N), abrasives concentration (C), workpiece material (Wp), abrasive mesh size (M), and magnetic flux density (Mf) upon response parameters, material removal rate (MRR) and change in surface roughness (ΔRa). The experimental results obtained for MRR and ΔRa show a significant improvement from 3.92 to 7.68 μg/s and 0.49 to 0.74 μm, respectively due to the increase of the extrusion pressure from 1 to 9 Mpa. The MRR and ΔRa was reduced from 6.89 to 6.78 μg/s and 0.46 to 0.22 μm, respectively with an increase in mesh number of abrasives from 80 to 400. The variation in concentration of abrasives from 40 to 60 % shows an improvement in MRR from 4.51 to 6.42 μg/s; whereas, there is a negligible effect on ΔRa which comes out from 3.82 to 3.86 μm. The MMCs, which are used for the experimentation shows a decline in MRR and ΔRa from 5.12 to 3.85 μg/s and 0.77 to 0.42 μm, respectively. This happened because there was a percentage change of reinforcement of SiC from 9 to 7 % and B4C from 1 to 3 % in Al-6063. An increase in the number of cycles from 50 to 250 shows a significant improvement in both MRR and ΔRa from 1.79 to 3.75 μg/s and 0.97 to 1.86 μm, respectively. Variation in magnetic effect also significantly improves MRR and ΔRa from 1.35 to 3.17 μg/s and 0.38 to 1.06 μm, respectively, when it is varied from 0.15 - 0.45 Tesla. The work carried out shows an overall significant improvement in MRR and ΔRa by using the MAFM process. The MAFM process finds a wide range of applications in finishing like surgical instruments, mechanical components, aerospace industry, electronics industry, etc. HIGHLIGHTS The hybrid MMCs (Al/SiC/B4C) are finished by novel MAFM setup An aluminium fixture and coil-type magnets play a significant role for finishing the workpiece surfaces An abrasive laden media acts as a cutting tool in the finishing process The OVAT approach is used for investigating the parametric effect The extrusion pressure, number of cycles and magnetic flux density are the significant parameters affecting the MRR and ΔRa GRAPHICAL ABSTRACT

Machine Assisted Experimentation of Extrusion-Based Bioprinting Systems

Optimization of extrusion-based bioprinting (EBB) parameters have been systematically conducted through experimentation. However, the process is time- and resource-intensive and not easily translatable to other laboratories. This study approaches EBB parameter optimization through machine learning (ML) models trained using data collected from the published literature. We investigated regression-based and classification-based ML models and their abilities to predict printing outcomes of cell viability and filament diameter for cell-containing alginate and gelatin composite bioinks. In addition, we interrogated if regression-based models can predict suitable extrusion pressure given the desired cell viability when keeping other experimental parameters constant. We also compared models trained across data from general literature to models trained across data from one literature source that utilized alginate and gelatin bioinks. The results indicate that models trained on large amounts of data can impart physical trends on cell viability, filament diameter, and extrusion pressure seen in past literature. Regression models trained on the larger dataset also predict cell viability closer to experimental values for material concentration combinations not seen in training data of the single-paper-based regression models. While the best performing classification models for cell viability can achieve an average prediction accuracy of 70%, the cell viability predictions remained constant despite altering input parameter combinations. Our trained models on bioprinting literature data show the potential usage of applying ML models to bioprinting experimental design.

Optimization parameters effects on electrical conductivity of 3D printed circuits fabricated by direct ink writing method using functionalized multiwalled carbon nanotubes and polyvinyl alcohol conductive ink

Fabrication of electronic circuits and the effects of optimization parameters on electrical conductivity of the printed circuits fabricated by direct ink writing method (D.I.W); one of the novel methods in 3D printing technologies is discussed in this work. This paper focuses on fabrication of electronic circuits using F-MWCNT/PVA conductive ink and analyses the effect of input printing process parameters namely nozzle diameter, extrusion pressure, printing speed on evaluating the electrical conductivity. Box–Behnken approach is followed to generate the levels of experiments and the performance of developed model is assessed using ANOVA. Response surface method is incorporated to find the influencing parameters on electrical conductivity response. Two-point probe measurement method is performed to analyse the output response of the printed electronic circuits. Optimized printing parameters such as nozzle diameter of 0.8 mm, extrusion pressure of 0.1 MPa and printing speed of 4 mm/sec are found to be the best the for printing electronic circuits with high electrical conductivity.

Bioprinting Using Algae: Effects of Extrusion Pressure and Needle Diameter on Cell Quantity in Printed Samples

Bioprinting is the fabrication of structures based on layer-by-layer deposition of biomaterials. Applications of bioprinting using plant or algae cells include the production of metabolites for use in pharmaceutical, cosmetic, and food industries. Reported studies regarding effects of extrusion pressure and needle diameter on cell viability in bioprinting have used animal cells. There are no reports regarding effects of extrusion pressure and needle diameter on cell viability using plant or algae cells. This paper fills this knowledge gap by reporting an experimental investigation on effects of extrusion pressure and needle diameter on cell quantity (an indicator of cell viability) in extrusion-based bioprinting of hydrogel-based bioink containing Chlamydomonas reinhardtii algae cells. Extrusion pressure levels used in this study were 3, 5, and 7 bar, and needle diameter levels were 200, 250, and 400 µm. Algae cell quantity in printed samples was measured on the third day and sixth day post bioprinting. Results show that, when extrusion pressure increases or needle diameter decreases, algae cell quantity in printed samples decreases.

Feasible Regions of Bioink Composition, Extrusion Pressure, and Needle Size for Continuous Extrusion-Based Bioprinting

Bioprinting has many potential applications in drug screening, tissue engineering, and regenerative medicine. In extrusion-based bioprinting, the extruded strand is the fundamental building block for printed constructs and needs to be of good quality and continuous in structure. In recent years, many studies have been conducted on extrusion-based bioprinting. However, values of process parameters leading to continuous extrusion of strands have rarely been reported. In this paper, feasible regions of bioink composition, extrusion pressure, and needle size for continuous strand extrusion have been evaluated. The information on feasible regions for extruding continuous strands, provided in this paper, can be useful in deciding appropriate extrusion pressure and needle size for the bioink of different compositions (ratios of alginate:methylcellulose) in extrusion-based bioprinting.

Experimental Investigation of Effects of Extrusion Pressure on Cell Growth of Bioprinted Algae Cells in Green Bioprinting

In bioprinting, biomaterials are deposited layer-by-layer to fabricate structures. Bioprinting has many potential applications in drug screening, tissue engineering, and regenerative medicine. Both animal cells and plant cells can be used to synthesize bioinks. Green bioprinting uses bioinks that have been synthesized using plant cells. Constructs fabricated via green bioprinting contain immobilized plant cells, with these cells arranged at desired locations. The constructs provide scaffolds for cell growth. Printing parameters affecting the growth of cells in green bioprinted constructs include print speed, needle diameter, extrusion temperature, and extrusion pressure. This paper reports a study to examine effects of extrusion pressure on cell growth (measured by cell count) in bioprinted constructs, using bioink containing Chlamydomonas reinhardtii algae cells. Three levels of extrusion pressure were used: 3, 5, and 7 bar. Cell counts in the bioprinted constructs were measured on the third and sixth days after bioprinting. It was found that, as extrusion pressure increased, cell count decreased on both the third and sixth days after bioprinting. Furthermore, the difference in cell counts between the third and the sixth days decreased as extrusion pressure increased. These trends suggest that increasing extrusion pressure during green bioprinting negatively affects cell growth. A possible reason for these trends is physical damage to or death of cells in the bioprinted constructs when extrusion pressure became higher.

Experimental Characterization and Finite Element Modeling of the Effects of 3D Bioplotting Process Parameters on Structural and Tensile Properties of Polycaprolactone (PCL) Scaffolds

In this study we characterized the process–structure interactions in melt extrusion-based 3D bioplotting of polycaprolactone (PCL) and developed predictive models to enable the efficient design and processing of scaffolds for tissue engineering applications. First, the effects of pneumatic extrusion pressure (0.3, 0.4, 0.5, 0.6 N/mm2), nozzle speed (0.1, 0.4, 1.0, 1.4 mm/s), strand lay orientation (0°, 45°, 90°, 135°), and strand length (10, 20, 30 mm) on the strand width were investigated and a regression model was developed to map strand width to the two significant parameters (extrusion pressure and nozzle speed; p < 0.05). Then, proliferation of NIH/3T3 fibroblast cells in scaffolds with two different stand widths fabricated with different combinations of the two significant parameters was assessed over 7 days, which showed that the strand width had a significant effect on proliferation (p < 0.05). The effect of strand lay orientation (0° and 90°) on tensile properties of non-porous PCL specimens was determined and was found to be significantly higher for specimens with 0° lay orientation (p < 0.05). Finally, these data were used to develop and experimentally validate a finite element model for a porous PCL specimen with 1:1 ratio of inter-strand spacing to strand width.

Finishing of Tubes using Bonded Magnetic Abrasive Powder in an Abrasive Medium

Magnetic abrasive flow finishing (MAFF) is an unconventional process capable of producing fine finishing with machining forces controlled by a magnetic field. This process can be utilized for hard to achieve inner surfaces through the activity of extrusion pressure, combined with abrasion activity of a magnetic abrasive powder (MAP) in a polymeric medium. MAP is the key component in securing systematic removal of material and a decent surface finish in MAFF. The research background disclosed various methods such as sintering, adhesive based, mechanical alloying, plasma based, chemical, etc. for the production of bonded MAP. This investigation proposes bonded MAP produced by mechanical alloying followed by heat treatment. The experiments have been conducted on aluminum tubes to investigate the influence of different parameters like magnetic field density, extrusion pressure and number of working cycles. The bonded magnetic abrasive powder used in MAFF is very effective to finish tubes’ inner surfaces and finishing is significantly improved after processing.