CSME Conference Proceedings (May 27-30, 2018)
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Browsing CSME Conference Proceedings (May 27-30, 2018) by Subject "3D printing"
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Item Open Access 3D Printing Of Metallic Structures From A Green Ink(CSME-SCGM, May-18) Xu, Chao; Bouchemit, Arslane; L'Espérance, Gilles; Lebel, Louis Laberge; Therriault, DaneilA green metallic ink is developed for 3D printing of metallic structures featuring high mechanical and electrical performances. The metallic ink consists of steel micro powders and a water-based chitosan/acetic acid polymer solution which replaces the previously used toxic polylactic acid (PLA)/dichloromethane (DCM) polymer solution. The optimized ink is printed at room temperature to build a metal/polymer hybrid structure. While printing, a fan is used to blow air over the ink filament upon extrusion to accelerate the solvent evaporation and shorten the solidification time, which significantly reduces the sagging and deformation. After a drying period at ambient conditions, the as-printed structure is then thermally treated using a furnace. The polymer binder is decomposed and the metal powders are sintered, resulting in a strong metallic structure. Melted copper is infiltrated into the sintered structure to achieve a fully dense metal/metal hybrid structure. The sintered structure exhibits high stiffness (205 GPa), electrical conductivity (9 × 105 S/m) and low filament porosity (7%).Item Open Access Constrained Topology Optimization For Additive Manufacturing Of Structural Components In Ansys®(CSME-SCGM, May-18) Jankovics, Davin; Gohari, Hossein; Barari, AhmadTopology Optimization is currently the main technique to optimize an objects structural design. This method commonly produces parts that have exceedingly complex geometry. Additive manufacturing (AM) is the main manufacturing process to produce these optimized designs due to the flexibility and speed it offers. However, results of topology optimization without considering manufacturing process limits, even AM ones, may result in designs that are expensive and difficult to build. This paper presents a topology optimization filter that minimizes the effect of overhang structures. These structures are very difficult to manufacture using conventional AM techniques. In order to constrain the gradient compliances with respect to densities and converge the results towards a structure with the least amount of overhang structures, sensitivities are modified using the proposed filter. To implement the proposed filter and the base topology optimization methods ESO and SIMP, ANSYS Parametric Design Language (APDL) is employed within the ANSYS® Workbench™ environment. The results of a case study using the different topology optimization methods are investigated. Finally, an implementation of the proposed AM filter is used to solve an MBB-beam problem. The result isItem Open Access Continuous Fiber Polymer Composites for Thermal Applications(CSME-SCGM, May-18) Elsayed, Yehia; Elkholy, Ahmed; Melenka, Garrett; Kempers, RogerThis paper presents an analytical investigation into the effective thermal conductivity of 3D printed continuous fibre polymer composites (CFPCs) using rule of mixture micro-structural analysis. Two fused deposition modelling techniques were utilized using a off-the-shelf printer and a low-cost modified printer. Results demonstrate significant improvement in the effective thermal conductivity of the composite compared to the base polymer. One samples was experimentally tested to examine the veracity of the model predictions.Item Open Access Material Properties Of 3D Printed Parts: Challenges In Design And Analysis(CSME-SCGM, May-18) Somireddy, Madhukar; Czekanski, AleksanderThe present paper addresses the challenges in design and analysis of 3D printed structures with anisotropic material properties. In recent years the additive manufacturing technologies have been used in most of the industries because of their freedom in fabrication of any complex geometry part. However, the final properties of the 3D printed parts are anisotropic though the material used is isotropic. Further, the properties of printed part are not homogeneous. This change in the properties is due to process parameters and build orientation of the parts. Therefore, this calls special attention of the designer for effective design and analysis of such parts. In this paper, design consideration of the parts for 3D printing and also, their structural analysis for effective design of parts for 3D printing are discussed. Further, different steps involved from design to 3D printing of a product are discussed.