Powder spreading in laser-powder bed fusion process

Mahdianikhotbesara

2022

Preprint

Self Cite

Among the advantages of the sheets used in the car body, it can mention the high strength, low thickness and suitable ductility. crack and wrinkling of the sheet are the most common types of defects in the drawing process. Therefore, it seems necessary to know the process factors that affect the sheet metal forming behavior. One of the critical tools of simulation and subsequent process optimization is the finite element method. In this research, with the help of AutoForm software, finite element simulation of the process is performed. After designing the appropriate Taguchi experiment, the parameters affecting the outputs, including thickness strain and surface strain on the production part, are investigated, and optimal values are introduced. The known effective parameters on the process output include the forming limit diagram, sheet strength, friction coefficient, die balancers, and used sheet thickness.

Section: Main Effects Plot For Sn Ratiosmentioning

confidence: 99%

A Numerical Study of Automotive Body Panel Draw Dies Defects Using Finite Element Simulation

Yadegari

Mahdianikhotbesara

2022

Preprint

Self Cite

“…inconel, titanium, aluminum) to build metallic parts layer by layer (Yang et al , 2016; Dinda et al , 2012; Guraya et al , 2019). However, due to the complicated powder performance, especially powder spreading (Sehhat and Mahdianikhotbesara, 2021), some challenges are difficult to overcome, examples of which are porosity, large powder surface area and induced oxidation (Jerrard et al , 2010; Mower and Long, 2016; Behdani et al , 2020). Also, the high price of powder is a major challenge and cost driver for typical LAM processes; to solve this cost limitation, recently, the researchers have successfully implemented the cheaper types of powder to provide highly desirable part properties, although the price of alternative powder type is still higher than metal foils (Sehhat et al , 2021c).…”

Section: Introductionmentioning

confidence: 99%

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Hung

Turk

et al. 2022

RPJ

Self Cite

Purpose This paper aims to present the development and experimental study of a fully automated system using a novel laser additive manufacturing technology called laser foil printing (LFP), to fabricate metal parts layer by layer. The mechanical properties of parts fabricated with this novel system are compared with those of comparable methodologies to emphasize the suitability of this process. Design/methodology/approach Test specimens and parts with different geometries were fabricated from 304L stainless steel foil using an automated LFP system. The dimensions of the fabricated parts were measured, and the mechanical properties of the test specimens were characterized in terms of mechanical strength and elongation. Findings The properties of parts fabricated with the automated LFP system were compared with those of parts fabricated with the powder bed fusion additive manufacturing methods. The mechanical strength is higher than those of parts fabricated by the laser powder bed fusion and directed energy deposition technologies. Originality/value To the best knowledge of authors, this is the first time a fully automated LFP system has been developed and the properties of its fabricated parts were compared with other additive manufacturing methods for evaluation.

“…Depending on the format of material feedstock, which can be powder, foil, paste, etc., the material feeding method to the AM process can be different [9] [10]. In powder-based AM methods, powder spreadability dominates the material feeding process to the AM system [11], while in the Fused Deposition Modeling (FDM) process the ability to extrude polymer material to the AM system is a role-player [12].…”

Section: Introductionmentioning

confidence: 99%

Impact of Temperature and Material Variation on Mechanical Properties of Parts Fabricated with Fused Deposition Modelling (FDM) Additive Manufacturing

Mahdianikhotbesara²,

Yadegari³

2022

Preprint

Self Cite

Additive Manufacturing (AM) can be deployed for space exploration purposes, such as fabricating different components of robots’ bodies. The produced AM parts should have desirable thermal and mechanical properties to withstand the extreme environmental conditions, including the severe temperature variations on moon or other planets which cause changes in parts’ strengths and may fail their operation. Therefore, the correlation between operational temperature and mechanical properties of AM fabricated parts should be evaluated. In this study, three different types of polymers, including polylactic acid (PLA), polyethylene terephthalate glycol (PETG), and acrylonitrile butadiene styrene (ABS), were used in Fused Deposition Modeling (FDM) process to fabricate several parts. The mechanical properties of produced parts were then investigated at various temperatures to generate knowledge on the correlation between temperature and type of material. When varying the operational temperature during tensile tests, the material’s glass transition temperature was found influential in determining the type of material failure. Among the materials used, ABS showed the best mechanical properties at all temperatures due to its highest glass transition temperatures. The results of statistical analysis indicated the temperature as the significant factor on tensile strength while the type of material was not a significant factor.