Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. It provides design freedom and environmental/ecological advantages. It transforms essentially design files to fully functional products. However, it is still hampered by low productivity, poor quality and uncertainty of final part mechanical properties. The root cause of undesired effects lies in the control aspects of the process. Optimization is difficult due to limited modelling approaches. Physical phenomena associated with additive manufacturing processes are complex, including melting/solidification and vaporization, heat and mass transfer etc. The goal of the current study is to map available additive manufacturing methods based on their process mechanisms, review modelling approaches based on modelling methods and identify research gaps. Later sections of the study review implications for closed-loop control of the process.

/pdf/additive-manufacturing-methods-and-modelling-approaches-a-2ln4lmzbbq.pdf

Additive manufacturing methods and modelling approaches: a critical review

Fused deposition modeling (FDM) is a rapidly growing 3D printing technology. However, printing materials are restricted to acrylonitrile butadiene styrene (ABS) or poly (lactic acid) (PLA) in most Fused deposition modeling (FDM) equipment. Here, we report on a new high-performance printing material, polyether-ether-ketone (PEEK), which could surmount these shortcomings. This paper is devoted to studying the influence of layer thickness and raster angle on the mechanical properties of 3D-printed PEEK. Samples with three different layer thicknesses (200, 300 and 400 μm) and raster angles (0°, 30° and 45°) were built using a polyether-ether-ketone (PEEK) 3D printing system and their tensile, compressive and bending strengths were tested. The optimal mechanical properties of polyether-ether-ketone (PEEK) samples were found at a layer thickness of 300 μm and a raster angle of 0°. To evaluate the printing performance of polyether-ether-ketone (PEEK) samples, a comparison was made between the mechanical properties of 3D-printed polyether-ether-ketone (PEEK) and acrylonitrile butadiene styrene (ABS) parts. The results suggest that the average tensile strengths of polyether-ether-ketone (PEEK) parts were 108% higher than those for acrylonitrile butadiene styrene (ABS), and compressive strengths were 114% and bending strengths were 115%. However, the modulus of elasticity for both materials was similar. These results indicate that the mechanical properties of 3D-printed polyether-ether-ketone (PEEK) are superior to 3D-printed ABS.

https://www.mdpi.com/1996-1944/8/9/5271/pdf

Influence of Layer Thickness and Raster Angle on the Mechanical Properties of 3D-Printed PEEK and a Comparative Mechanical Study between PEEK and ABS

Fused deposition modelling (FDM) is the most economical additive manufacturing technique. The purpose of this paper is to describe a detailed review of this technique. Total 211 research papers published during the past 26 years, that is, from the year 1994 to 2019 are critically reviewed. Based on the literature review, research gaps are identified and the scope for future work is discussed.,Literature review in the domain of FDM is categorized into five sections – (i) process parameter optimization, (ii) environmental factors affecting the quality of printed parts, (iii) post-production finishing techniques to improve quality of parts, (iv) numerical simulation of process and (iv) recent advances in FDM. Summary of major research work in FDM is presented in tabular form.,Based on literature review, research gaps are identified and scope of future work in FDM along with roadmap is discussed.,In the present paper, literature related to chemical, electric and magnetic properties of FDM parts made up of various filament feedstock materials is not reviewed.,This is a comprehensive literature review in the domain of FDM focused on identifying the direction for future work to enhance the acceptability of FDM printed parts in industries.

Fused deposition modelling: a review

Current status and future directions of fused filament fabrication

The mechanical testing and performance analysis of polymer-fibre composites prepared through the additive manufacturing

Comparative between FEM models for FDM parts and their approach to a real mechanical behaviour.

Summary: In order to ensure flexibility and rapid new product development, the mold industry made use of soft materials for cavity inserts in injection molds. However, materials of this kind are prone to wear. This article analyzes the topographic characterization of the surface and wear processes in injection molds cavities. Two materials have been used to produce the cavities: aluminum alloy EN AW‐6082 T4 and copper alloy Cu Zn39 Pb3. The surface topography was measured with the use of optical interferometry profiling technology; roughness and surface parameters were determined according to ISO 4287, ISO 25178, and EUR 15178N. In order to complete this research, an experimental part with different thicknesses and shapes was designed, and cavity inserts of aluminum and copper were made. Polyamide PA6, with 30% fiberglass reinforcement, was employed in the experimental procedure. Measurements of cavity mold surfaces were performed after 9,200 cycles on each mold and at different locations on the mold. The surface measurement was made with a white light vertical scanning interferometry, also known as coherence scanning interferometry (ISO DIS 25178‐ 604). The results are analyzed and differences between the two types of cavity inserts materials are discussed. SCANNING 36: 39–52, 2014. © 2013 Wiley Periodicals, Inc.

Surface topographic characterization for polyamide composite injection molds made of aluminum and copper alloys

Biotecnología del azafrán

FDM is one of the rapid prototyping techniques. Although the large number of advantages of these techniques, the surface quality of the built parts is, in most cases, far away from the required value. This means that the use of post-processing steps is necessary and thus, the total manufacturing time is significantly increased. However with an optimal selection of few parameters during the design and manufacturing steps the surface quality can be improved considerably without post-processing steps. In the present research, three different cases are studied: one for plane surfaces, one for concave surfaces and another for convex surfaces. Using Taguchi method and ANOVA analysis it is determined which parameters among layer thickness, inclination, rotation along z-axis and the radio have more influence in the surface quality of each type of surface, and which their optimal levels are. Also, a regression model that relates these parameters with the surface quality is shown for each case. These models permit to have prior knowledge about the final roughness of the surfaces. Thus, this study gives complete information that permits designers and users of FDM process to calculate, in a very simple and quick way, an approximate surface roughness of the part before building it, and if this is not the require value, they know which are the main parameters and in which direction they can change them to get better results.

Modelization of Surface Roughness in FDM Parts

The main objective of this research is study the wear of a mould, made in easy machining material; aluminium EN AW-6082 T4 and the surface characterization of mould cavity, used in a polymeric manufacturing process, after several injection cycles To evaluate the effectiveness of this materials in the plastic injection process, a test part with different thicknesses and shapes was designed and some inserts of aluminium were made In the way of plastic material, a 30 % fiberglass reinforced polyamide PA6 has been employed in the experimental procedure A reusable injection mould was used and surface measurements of mould cavity have been performed after 9200 cycles The surface topography has been measured by using optical interferometry profiling technology and there have also been obtained roughness and surface parameters according to ISO 25178 and EUR15178N In order to surface characterization, different areas of the mould cavity with different geometries, has been analysed The behaviour of wear rate has been analysed by the study of the evolution of the surface parameters and functional parameters in different points of the surface mould

/pdf/study-of-morphology-wear-model-of-moulds-from-alloys-of-2q89ec9079.pdf

Study of Morphology Wear Model of Moulds from Alloys of Aluminium EN AW-6082 in Injection Process

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