Additive manufacturing (AM) is a layer-by-layer manufacturing process. However, its broad adoption is still hindered by limited material options, different fabrication defects, and inconsistent part quality. Material extrusion (ME) is one of the most widely used AM technologies, and, hence, is adopted in this research. Low-cost metal ME is a new AM technology used to fabricate metal composite parts using sintered metal infused filament material. Since the involved materials and process are relatively new, there is a need to investigate the dimensional accuracy of ME fabricated metal parts for real-world applications. Each step of the manufacturing process, from the material extrusion to sintering, might significantly affect the dimensional accuracy. This research provides a comprehensive analysis of dimensional changes of metal samples fabricated by the ME and sintering process, using statistical and machine learning algorithms. Machine learning (ML) methods can be used to assist researchers in sophisticated pre-manufacturing planning and product quality assessment and control. This study compares linear regression to neural networks in assessing and predicting the dimensional changes of ME-made components after 3D printing and sintering process. In this research, the ML algorithms present a significantly high coefficient of determination (i.e., 0.999) and a very low mean square error (i.e., 0.0000878). The prediction outcomes using a neural network approach have the smallest mean square error among all ML algorithms and it has quite small p-values. So, in this research, the neural network algorithm has the highest accuracy. The findings of this study can help researchers and engineers to predict the dimensional variations and optimize the printing and sintering process parameters to obtain high quality metal parts fabricated by the low-cost ME process.
Abstract. In this work, a heat transfer study is carried out in a convective-radiative straight fin with temperature-dependent thermal conductivity and a magnetic field using the variation of parameters method. The developed heat transfer model is used to analyze the thermal performance, establish the optimum thermal design parameters and investigate the effects of thermo-geometric parameters and non-linear thermal conductivity parameters on the thermal performance of the fin. The results obtained are compared with the results in literature and good agreements are found. The analysis can serve as basis for comparison of any other method of analysis of the problem and it also provides a platform for improvement in the design of fin in heat transfer equipment. MSC 2010: 35A15
Additive manufacturing (AM) is an emerged layer-by-layer manufacturing process. However, its broad adoption is still hindered by limited material options, different fabrication defects, and inconsistent part quality. Material extrusion (ME) is one of the most widely used AM technologies, and, hence, is adopted in this research. Low-cost metal ME is a new and AM technology used to fabricate metal composite parts using sintered metal infused filament material. Since the involved materials and process are relatively new, there is a need to investigate the dimensional accuracy of ME fabricated metal parts for real-world applications. Each step of the manufacturing process, from the material extrusion to sintering, might significantly affect the dimensional accuracy. This research provides a comprehensive analysis of dimensional changes of metal samples fabricated by the ME and sintering process, using statistical and machine learning algorithms. Machine learning (ML) methods can be used to assist researchers in sophisticated pre-manufacturing planning and product quality assessment and control. This study compares linear regression to neural networks in assessing and predicting the dimensional changes of ME made components after 3D printing and sintering process. The prediction outcomes using a neural network performed the best with the highest accuracy as compared to regression. The findings of this study can help researchers and engineers to predict the dimensional variations and optimize the printing and sintering process parameters to obtain high quality metal parts fabricated by the low-cost ME process.
Impedance-based structural health monitoring (SHM) is recognized as a non-intrusive, highly sensitive, and model-independent SHM solution that is readily applicable to complex structures. This SHM method relies on analyzing the electromechanical impedance (EMI) signature of the structure under test over the time span of its operation. Changes in the EMI signature, compared to a baseline measured at the healthy state of the structure, often indicate damage. This method has successfully been applied to assess the integrity of numerous civil, aerospace, and mechanical components and structures. However, EMI sensitivity to environmental conditions, the temperature, in particular, has been an ongoing challenge facing the wide adoption of this method. Temperature-induced variation in EMI signatures can be misinterpreted as damage, leading to false positives, or may overshadow the effects of incipient damage in the structure. In this paper, a new method for temperature compensation of EMI signature is presented. Data-driven dynamic models are first developed by fitting EMI signatures measured at various temperatures using the Vector Fitting algorithm. Once these models are developed, the dependence of model parameters on temperature is established. A parametric data-driven model is then derived with temperature as a parameter. This allows for EMI signatures to be calculated at any desired temperature. The capabilities of this new temperature compensation method are demonstrated on aluminum samples, where EMI signatures are measured at various temperatures. The developed method is found to be capable of temperature compensation of EMI signatures at a broad frequency range.
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