Application of Reverse Engineering for Automotive Plastic Components – Case Study

Tămăşag, Ioan; Beşliu, Irina; Dumitru, Adrian

doi:10.1002/masy.202000265

Cited by 4 publications

(3 citation statements)

References 15 publications

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“…In the FDM process, also known as the MEX (material extrusion) process [ 4 ], one of the most widely used materials, at the expense of petroleum-based polymers [ 5 , 6 ], is polylactic acid (PLA), a polymer that has a semi-crystalline structure, is biodegradable, and has good physical properties. Since the manufacturing process results in parts with low mechanical and thermal properties [ 6 , 7 , 8 , 9 ], the literature also presents different methods to improve these properties by reinforcing the polymer with other materials such as carbon fibre [ 10 ], glass fibre [ 11 ], and natural fibre [ 12 ], and post-processing methods, such as heat treatment [ 13 , 14 , 15 ] or chemical treatment [ 16 , 17 ], which involve additional steps and costs, thus also increasing the manufacturing time. Regarding the application of heat treatment on parts made of PLA by the FDM method, several research studies have been carried out [ 14 , 18 , 19 , 20 , 21 , 22 ], and it has been proven that the mechanical properties of the tested specimens improved drastically when the obtained parts were subjected to heat treatment post-processing.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study of In-Process Heat Treatment on the Mechanical Properties of 3D Printed Thermoplastic Polymer PLA

et al. 2023

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The scientific literature regarding additive manufacturing, mainly the material extrusion method, suggests that the mechanical characteristics of the parts obtained by this technology depend on a number of the input factors specific to the printing process, such as printing temperature, printing trajectory, layer height, etc., and also on the post-process operations for parts, which, unfortunately, requires supplementary setups, equipment, and multiple steps that raise the overall costs. Therefore, this paper aims to investigate the influence of the printing direction, the thickness of the deposited material layer, and the temperature of the previously deposited material layer on the part tensile strength, hardness by means of Shore D and Martens hardness, and surface finish by using an in-process annealing method. A Taguchi L9 DOE plan was developed for this purpose, where the test specimens, with dimensions according to ISO 527-2 type B, were analysed. The results showed that the presented in-process treatment method is possible and could lead to sustainable and cost-effective manufacturing processes. The varied input factors influenced all the studied parameters. Tensile strength tended to increase, up to 12.5%, when the in-process heat treatment was applied, showed a positive linear variation with nozzle diameter, and presented considerable variations with the printing direction. Shore D and Martens hardness had similar variations, and it could be observed that by applying the mentioned in-process heat treatment, the overall values tended to decrease. Printing direction had a negligible impact on the additively manufactured parts’ hardness. At the same time, the nozzle diameter presented considerable variations, up to 36% for Martens hardness and 4% for Shore D, when higher diameter nozzles were used. The ANOVA analysis highlighted that the statistically significant factors were the nozzle diameter for the part’s hardness and the printing direction for the tensile strength.

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Section: Introductionmentioning

confidence: 99%

Experimental Study of In-Process Heat Treatment on the Mechanical Properties of 3D Printed Thermoplastic Polymer PLA

et al. 2023

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“…Before making the injection mold, injection molding numerical analysis and machine learning were conducted to predict the warpage of automotive parts [22]. 3D scan operation was carried out to create a product model and use it as an injection mold design data before making an injection mold [23][24][25].…”

Section: Introductionmentioning

confidence: 99%

Optimization of Injection Molding of Automotive Plastic Horn Cover Part Using Taguchi Method and Reverse Engineering

Lee¹,

Cho²,

Han³

2022

Mater. Plast.

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The aim of the paper consisted in the development of an injection mold for plastic horn cover parts in commercial vehicles. Three mold types were designed in anticipation of the structure and quality of molds, and injection molding numerical analyses were conducted for the three types of molds. One mold type was selected in consideration of the resin flow patterns inside the mold, surface quality, and final deflection amount of the horn cover. To perform optimal injection molding using the selected mold, optimization of injection molding parameters was performed using the Taguchi method, one of the designs of experiment (DOE) and ANOVA methods. As a result, it was confirmed that the deflection amount of the molding under optimal molding parameters decreased by about 34.3% compared to the deflection amount before optimization of the molding parameters. Based on these encouraging results, the previously selected mold type was actually manufactured. The horn cover was molded using the obtained optimal injection molding parameters to the manufactured mold. To verify the precision of the molded horn cover, the deflection amount of the molding was measured with a 3D scanner. The deflection amount of the horn cover was estimated to be about 11% to 43% larger for each measurement position than the deflection amounts in the analysis results. The manufactured mold was revised to solve the problem that the deflection amount of the actual molding is larger than the deflection amount predicted by injection molding analysis. The dimensions and surface quality of the horn cover with a revised mold were satisfactory.

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“…At the same time, although the literature suggests that the dimensional accuracy does not change substantially, some information regarding the smoothing effect of the edges of the parts has been found [6], especially of the parts with very sharp edges. However, the FDM process has expanded to other areas such as aerospace, automotive [19], medical, etc. [20,21], areas in which the parts must have the best possible dimensional accuracy, and thus the deformations due to the acetone steam treatment must be as small as possible.…”

Section: Introductionmentioning

confidence: 99%

Some Insights on Chemical Treatment of 3D Printed Parts

Tămăşag¹,

Dumitru²,

Beşliu³

2022

Mater. Plast.

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The substantial increase in the use of the FDM (Fused Deposition Modeling) process for the production of plastic parts in ever wider fields has led to the search for methods to improve the quality of the printed parts. In the case of ABS parts (Acrylonitrile Butadiene Styrene), one of the most common and used methods to improve surface quality is the process of acetone steam treatment, but the application of this method also brings more or less negative effects on the part. The main side effects when applying this method is the low breaking strength and loss of part details on the sharp edges. This paper presents a set of contributions on the relationship between surface quality and the level of detail of parts subjected to acetone steam treatment. In order to analyze the influence of the treatment on the details of the parts, a reverse engineering method was used in which a polyarticular arm FARO Edge 7.5 was used to scan the parts and reconstruct them. The study was performed on parts with 20% infill, grid tipe.

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Application of Reverse Engineering for Automotive Plastic Components – Case Study

Cited by 4 publications

References 15 publications

Experimental Study of In-Process Heat Treatment on the Mechanical Properties of 3D Printed Thermoplastic Polymer PLA

Experimental Study of In-Process Heat Treatment on the Mechanical Properties of 3D Printed Thermoplastic Polymer PLA

Optimization of Injection Molding of Automotive Plastic Horn Cover Part Using Taguchi Method and Reverse Engineering

Some Insights on Chemical Treatment of 3D Printed Parts

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