Improving the quality of a circular cooling channel fabrication by fused filament fabrication using Taguchi methods

Kuo, Chil-Chyuan; Tasi, Qing-Zhou; Xie, Bing-Xiu; Huang, Jian; Qiu, Shao-Xuan

doi:10.1007/s00170-022-08986-8

Cited by 13 publications

(4 citation statements)

References 30 publications

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“…Three different S/N quality characteristic formulations are shown in the following equations. To investigate the optimum process parameters for fabricating a power case with the highest weld strength, the orthogonal array (OA) [28] was employed in this study since it is suitable for the four process control factors with three levels. In general, analysis of variance (ANOVA) is frequently used to compare the difference between the means of the groups.…”

Section: Methodsmentioning

confidence: 99%

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

Kuo

Tsai

et al. 2022

Polymers

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Ultrasonic welding (UW) is a joining of plastics through the use of heat generated from high-frequency mechanical motion, which is known as an efficient process in many applications, such as textile, packaging, or automotive. UW of thermoplastics has been widely employed in industry since no polymer degradations are found after UW. However, the trial-and-error approach is frequently used to study optimum UW process parameters for new 3C plastic power cases in current industry, resulting in random efforts, wasted time, or energy consumption. In this study, Taguchi methods are used to study optimum UW process parameters for obtaining high weld strength of a plastic power case. The most important control factor influencing the weld strength is amplitude, followed by weld pressure, hold time, and trigger position. The optimum UW process parameters are amplitude of 43.4 µm, weld pressure of 115 kPa, hold time of 0.4 s, and trigger position of 69.95 mm. Finally, the confirmation experiments are performed to verify the optimum process parameters obtained in this study.

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Section: Methodsmentioning

confidence: 99%

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

Kuo

Tsai

et al. 2022

Polymers

Self Cite

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“…There are research studies, such as [17] and [18], in which the process parameters are investigated and optimized with respect to the manufacturing of specific geometries. Findings of such studies in terms of geometrical limits are not suitable for a more general transfer, but emphasize the potential for interactions between process and design.…”

Section: Manufacturingmentioning

confidence: 99%

Methodical Development of data driven quantitative Design Rules in Additive Manufacturing

Stachg,

Telgkamp

2023

Preprint

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Additive manufacturing (AM) and its industrial application are growing steadily.However, despite many research efforts, there are challenges in the practical implementation.In addition to methodological challenges within the design process, the detailed design of AM components, which is suited for manufacturing as well as economically beneficial, poses difficulties.As an improvement of the situation, a methodical framework is presented, through which design rules for a practice-oriented design of AM geometries can be developed.The design rules developed based on this framework are of qualitative as well as quantitative nature.The qualitative perspective is concerned with the question of whether the geometries can be manufactured depending on their features.The quantitative perspective is concerned with the quality of the manufactured geometries depending on their features.Within this framework, the potential influence of process parameters on part quality is addressed.The method is based on applied statistics on the one hand and uses methods of explorative data analysis on the other hand.A case study is conducted to demonstrate the framework.This study consists of the development of a quantitative design rule for a geometry element (hollow cylinder) with reference to a material extrusion process.The results of the case study are statistical models for various quality characteristics (diameter deviations and cylindricity).The terms of the models are obtained by regression and are then statistically tested for significance.The models set up also allow an assessment of the achievable tolerance grades for geometric features investigated and their respective quality characteristics.

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“…Among the stages of the molding cycle, the cooling phase is the one with the highest energy and time consumption, which constitutes around 70% of the total cycle manufacturing time [ 15 , 16 , 17 ]. In a conventional molding process, water, acting as a coolant, flows continuously through a set of channels in the mold, thus starting the solidification process of the injected melt when it comes into contact with the surface of the cavity at a lower temperature [ 18 , 19 ].…”

Section: Introductionmentioning

confidence: 99%

Application of New Conformal Cooling Layouts to the Green Injection Molding of Complex Slender Polymeric Parts with High Dimensional Specifications

et al. 2023

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Eliminating warpage in injection molded polymeric parts is one of the most important problems in the injection molding industry today. This situation is critical in geometries that are particularly susceptible to warping due to their geometric features, and this occurs with topologies of great length and slenderness with high changes in thickness. These features are, in these special geometries, impossible to manufacture with traditional technologies to meet the dimensional and sustainable requirements of the industry. This paper presents an innovative green conformal cooling system that is specifically designed for parts with slender geometric shapes that are highly susceptible to warping. Additionally, the work presented by the authors investigates the importance of using highly conductive inserts made of steel alloys in combination with the use of additively manufactured conformal channels for reducing influential parameters, such as warpage, cooling time, and residual stresses in the complex manufacturing of long and slender parts. The results of this real industrial case study indicated that the use of conformal cooling layouts decreased the cycle time by 175.1 s—66% below the current cooling time; the temperature gradient by 78.5%—specifically, 18.16 ºC; the residual stress by 39.78 MPa—or 81.88 %; and the warpage by 6.9 mm—or 90.5%. In this way, it was possible to achieve a final warping in the complex geometry studied of 0.72 mm, which was under the maximum value required at the industrial level of 1 mm. The resulting values obtained by the researchers present a turning point from which the manufacturing and sustainability in the injection molding of said plastic geometries is possible, and they take into account that the geometric manufacturing features analyzed will present a great demand in the coming years in the auto parts manufacturing industry.

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Improving the quality of a circular cooling channel fabrication by fused filament fabrication using Taguchi methods

Cited by 13 publications

References 30 publications

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

Methodical Development of data driven quantitative Design Rules in Additive Manufacturing

Application of New Conformal Cooling Layouts to the Green Injection Molding of Complex Slender Polymeric Parts with High Dimensional Specifications

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