Generative design is a technique that effectively produces lightweight yet structurally robust co... more Generative design is a technique that effectively produces lightweight yet structurally robust components. However, the final result is highly dependent upon manufacturing constraints during the design phase. This work investigates how machining, 3D printing, and die casting constraints shape a reengineered car brake pedal. Each option was constructed within Autodesk Fusion 360 using identical loads and fixations and material characteristics. Variations in performance were evaluated by FEA with respect to weight, stress pattern, stiffness, movement under load, and safety margin. In contrast, the greatest mass reduction was attained by the AM-based design; the mass dropped from 1.36 kg to 0.58 kg, a 41.3% drop, while still meeting the minimum required safety margin of at least 2.0. Meanwhile, the average mass for the die-cast design reached 0.70 kg, based on proper taper and thickness rules of the part while maintaining strength. On the contrary, the machined-limited part had the heaviest mass value of 2.77 kg. Nevertheless, it portrayed the highest stiffness; besides that, it attained the highest safety value, FoS = 5.84, highlighting how subtractive manufacturing methods sacrifice mass for durability. Manufacturing limits impact geometric design results by limiting feasible forms while varying mechanical component functionalities. Accordingly, this paper presents an investigation into different manufacturing techniques and their impacts on design solutions, using examples of different techniques to highlight efficiency. Ways of proposing lighter brake pedal designs that are easier to produce involve adjusting material usage while easing assembly steps to enhance feasibility without compromising performance.
El cezeri Journal of Science and Engineering, 2024
The primary objective of this research is to examine the effects of annealing temperature and dur... more The primary objective of this research is to examine the effects of annealing temperature and duration on the surface quality and tensile strength of ABS-printed materials. ASTM 638 Type IV specimens were created in SolidWorks, sliced using Ultimaker Cura 4.4, and printed with a Creality Ender 3 3D printer using 1.75 mm ABS filament. The samples were subjected to thermal annealing at temperatures ranging from 120 • C to 180 • C. The annealing durations were set at 20, 40, and 60 minutes, after which the samples were cooled down to room temperature. The TR200 roughness tester and Instron 5585 tensile testing machine were utilized to measure surface roughness and tensile strength, respectively. The smoothest surface (0.622µm) was obtained when the temperature was set at 120 • C for a duration of 20 minutes. On the other hand, the roughest surface (3.246µm) was observed when the temperature was increased to 180 • C and maintained for a longer period of 60 minutes. The highest tensile strength of 75.681 MPa was observed at a temperature of 180 • C for a duration of 60 minutes, indicating an optimal condition for maximizing the strength of ABS. However, there may be a limit, as suggested by previous research conducted at temperatures of 160 • C and 180 • C. In conclusion, it can be observed that the relationship between annealing temperature, duration, and surface roughness is not solely linear. The variations observed indicate the presence of interactions between these factors.
Convergent-divergent (CD) nozzles are critical components in aerospace propulsion systems. The ch... more Convergent-divergent (CD) nozzles are critical components in aerospace propulsion systems. The challenges in the CD nozzle design involve minimizing the flow separation and shock wave formation at divergent sections, which can affect the thrust and overall performance. The objective of this study is to investigate the effects of divergence angles on exit velocity, thrust and pressure drop. By utilizing ANSYS Fluent for simulations, the research explores CD nozzles with divergence angles of 7°, 13° and 19° with and without a throat length of 0.3 m. Boundary conditions of inlet pressure, mass flow rate and temperature were constant at 4.41 MPa, 826 kg/s and 3400 K respectively. Grid independence tests are employed to ensure simulation accuracy. The result shows, that higher divergence angles increase exit velocities, Mach numbers, thrust forces and pressure drop. The inclusion of a throat length notably improves these parameters by smoothing flow transition and expanding the air more efficiently at the divergent sections, converting more pressure energy into kinetic energy. The thrust force increases with higher divergence angles with the presence of the throat length as it enhances momentum rates. Model 6 which has a divergence angle of 19°and throat length provides optimal performance for the CD nozzle with a thrust force of 2056.91 kN and pressure drop which is 3959.8 kPa. Using suitable divergence angles and adding a throat length significantly enhances the effectiveness of CD nozzles.
This study examines the influence of filament color on optimizing FDM process parameters for PLA ... more This study examines the influence of filament color on optimizing FDM process parameters for PLA parts using the Taguchi method. Parameters such as layer thickness, print speed, and printing temperature were varied to identify optimal settings for white and black PLA filaments. The results demonstrate that the optimal parameters vary based on color: for white PLA, the best configuration involves a layer thickness of 0.35 mm, print speed of 50 mm/s, and a printing temperature of 210°C. For black PLA, the same layer thickness and print speed are optimal, but the printing temperature is lower at 200°C. Layer thickness was identified as the most significant factor affecting tensile strength across both filament types. However, the ideal printing temperature depended on the color of the filament. Notably, white PLA exhibited higher tensile strength than black PLA, with an increase ranging from 1.33% to 15.54%, attributed to the thermal properties of color pigments. These findings highlight the critical role of filament color in determining mechanical performance during FDM printing. Incorporating filament color into the optimization of FDM parameters can enhance the quality, strength, and reliability of 3D-printed components. This research provides valuable insights for improving additive manufacturing outcomes across a range of applications.
The Effects of Varying Oxygen Concentrations on Tensile Strength and Surface Roughness of 3D Printer
Effect of Process Parameters on Void Formation in Fused Deposition Modelling (FDM) Part
Suranaree Journal of Science and Technology
A void is a structural defect resulting from the 3D printing process. The presence of voids compr... more A void is a structural defect resulting from the 3D printing process. The presence of voids compromises the structural integrity of a 3D-printed component, resulting in a reduction in durability and functionality. Currently, the only technique used to correlate FDM process parameters with mechanical properties is tensile testing. Nonetheless, this method is time-consuming and expensive. Therefore, the purpose of this study is to determine the viability of employing an alternative method to establish this connection. This study examined the parameters of infill density, infill pattern, raster angle, and part shape. While pressurized gas release was used to evaluate the printed material based on bubble formation, the printed object was evaluated based on bubble formation. Subsequently, the qualitative relationship between these parameters, void formation, and mechanical properties was determined. According to the results of this study, the relationship between the studied parameters, ...
The nozzle of a 3D printer extrudes molten filament onto the print surface. The detachable and ad... more The nozzle of a 3D printer extrudes molten filament onto the print surface. The detachable and adjustable nozzle of a 3D printer allows for the printing of lines of varying thickness. This study intends to investigate the effect of nozzle diameter on the tensile and flexural properties of printed specimens. The tensile and flexural specimens were prepared according to ASTM D638 Type 1 and ISO 178, respectively. After specimens were printed with nozzles having diameters of 0.3, 0.4, 0.5, 0.6, and 0.8 mm, tensile and flexural tests were conducted using an Instron 5585 machine. Each specimen was printed with 0.2 mm layer thickness, a line pattern, and 100 percent infill. Tensile and flexural behaviors of PLA specimens were comparable, according to the findings. Tensile and flexural strengths increase as nozzle diameter increases, but they are only effective up to a certain diameter. At a nozzle diameter of 0.6 mm, the maximum tensile strength was 33.32 MPa, and at a nozzle diameter of ...
Wire and arc additive manufacturing (WAAM) has developed a wide range of processes and applicatio... more Wire and arc additive manufacturing (WAAM) has developed a wide range of processes and applications. This technology is a new approach to modern manufacturing and is gaining interest from the research community due to its ability to create affordable, large-scale components. Nevertheless, WAAM may affected by porosity, humping and undercut. These issues need to be addressed in a specific way to achieve desired quality that is comparable to the traditional processing technique. This article examines various weld travel speeds, where defects start appearing. The effects of travel speed and wire feed speed (WFS) were also discussed. It was found that, travel speed and WFS had a major influence on deposition width and height and a stable deposited layer was produced between heat input values of 0.2620 kJ/mm and 0.32756 kJ/mm.
Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM), 2017
Additive manufacturing or 3D printing is a technology that built 3D objects by adding material la... more Additive manufacturing or 3D printing is a technology that built 3D objects by adding material layer-by-layer. There are tremendous studies have been conducted regarding this new emerging technology to transform the printed part from being a prototyping tool to a manufacturing process that can create durable and functional goods, and comparable to the traditional manufacturing processes. Therefore, this study proposes a new method of Fused Filament Fabrication (FFF) by integrating with mechanical pressing where a roller is used to improve the strength and porosity of the printed part during processing. This study focuses on the low-range RepRap 3D printer. Mendel RepRap was used to print the samples, and the material of Acrylonitrile-butadiene-styrene (ABS) was used for this study. The samples printed from both techniques, normal FFF and FFF with pressing were compared with respect to their tensile strength and porosity. The strength of the samples was tested using an Instron machine, and the images of the samples were captured using Scanning Electron Microscope (SEM). Later, Image J software was used to analyze and calculate the percentage of the porosity. Based on the results, the percentage of porosity for the normal FFF is about 20~21% while FFF with pressing shows the smaller value that ranges from 12~15%. Meanwhile, the tensile strength of the FFF with pressing gave a greater value which is up to 38.34 Mpa.
Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM), 2018
3D printing or also known as additive manufacturing (AM) processes fabricate complex mechanical s... more 3D printing or also known as additive manufacturing (AM) processes fabricate complex mechanical structures by using deposition of the filaments layer by layer technique. AM process has a good capability to fabricate the complex structure compares to conventional machining. However, there is limited design guideline for AM even for the most used AM technique which is fused deposition modeling technique (FDM). Thus, in this paper, various mechanical structures such as overhangs, bridges, wall thickness, hole diameter and vertical wire diameter were fabricated to study the manufacturability of the design structure fabricated by entry level 3D printer using polylactic acid (PLA) material. The parts manufactured were then measured to evaluate the dimensional accuracy and deviations between 3D computer-aided design (CAD) and nominal data. Based on the results, design guidelines for each respective mechanical structure have been recommended.
This work describes the early segmentation results in the progress of a mechanism design process ... more This work describes the early segmentation results in the progress of a mechanism design process to produce simple planar machines that could approximate a shape change defined by a set of curves with significant differences in arc length. The design profiles vary from one another by a combination of rigid-body displacement and shape change that includes significant differences in arc length. Where previous rigid-body shape-change work focused on mechanisms composed of rigid links and revolute joints to approximate curves of roughly equal arc length, this work introduces prismatic joints into the mechanisms in order to produce the different desired arc lengths. The first step is to convert the design profiles into piecewise linear curves, referred to as target profiles. The piecewise linear representation that proves most useful has points identified along the curve at roughly equal distances. The second step is to compare segments of the target profiles seeking those that are bes...
This paper investigates the effectiveness and the accuracy of open source 3D printer of Mendel Ma... more This paper investigates the effectiveness and the accuracy of open source 3D printer of Mendel Max and Kossel Mini which the additive manufacturing technique of Fused Filament Fabrication (FFF) was implemented.A benchmark of the 3D printer test model was designed based on critical features of AM process i.e. hemispheres, cube,cylindersand slots.The benchmark was produced by both machines using variation FFF parameters of layer height and infill density.In addition,the material of FFF was varied between PLA and ABS for each test.The dimensional accuracy of the part features were measured by the nominal dimension of the part using Profile Projector DS600.In addition,TR200 roughness tester was used to measure the surface roughness.The result shows that for dimensional accuracy results,Mendel Max machine has a lower deviation result compared to Kossel machine. Furthermore,PLA filament gives better result compare to ABS filament in term of surface quality finishing for both machines.The ...
Novel Prediction Reliability Model Using Small Hydro Power Optimization Tool For Performance Investigation
Generation of small hydropower is based on potential energy from the flowing water to produce ele... more Generation of small hydropower is based on potential energy from the flowing water to produce electricity. Even though there is less implementation in Peninsular Malaysia, this small hydropower system can provide more benefits in electricity generation especially rural application. Streamflow is the volume of water flow passes through a specific point on a given period of time. Besides, The feasibility study of the streamflow is the key component factor in installation of small hydropower system and finding the best fitted distribution will helps in provide the most suitable prediction distribution function of the streamflow for further used. Extreme Values Family’s and Log-normal distribution are used and parameter estimation is using MLE method.
Conductive ink is a special type of ink which allows current to flow through the ink. There are s... more Conductive ink is a special type of ink which allows current to flow through the ink. There are several varieties of conductive inks in the market and it is crucial to choose a suitable ink for the electronic applications. Graphene material is chosen to replace the current ink due to its promising properties that have been explored by many researchers. This paper aims to investigate the effect of temperature and percentage of graphene ink on hardness and Young's modulus of printed graphene ink samples. Samples were fabricated using a simple method involving formulating, mixing, printing and curing processes and the ink was printed on the glass slide substrate. The samples were cured at 160°C and 180°C for one hour. The mechanical properties of printed graphene ink sample were evaluated using Dynamic Ultra Micro Hardness (DUMH). All the measurements were done with the same force of indentation to avoid the possibility of perforation of printed graphene ink. The results show that ...
Fused deposition modeling (FDM) is a 3D printing/additive manufacturing (AM)technology that creat... more Fused deposition modeling (FDM) is a 3D printing/additive manufacturing (AM)technology that creates a part layer by layer.However,the printed parts have poor surface finish and staircase effect,which is the inherent characteristics of FDM printed parts.This contributes to poor quality of the final components.Thus,in this paper, post process treatment on 3D printed part by using blow cold vapor has been made.The parts were fabricated by using the open-source 3D printer with acrylonitrile-butadiene-styrene (ABS) material.Then,after the treatment,the surface finish and the mechanical properties of the parts were analyzed.The cold vapor treatment using chemical agents,namely acetone and methyl-ethyl-ketone (MEK).A comparison was made between the parts before and after treatment.It is found that the proposed method is able to improve the surface finishing of FDM parts.However,the method has affected the tensile strength where there is a slight decrease in the strength value.
International Journal of Engineering and Advanced Technology, 2020
This work analyzes the feasibility of a design of a foldable chair that is strapped onto the user... more This work analyzes the feasibility of a design of a foldable chair that is strapped onto the user. It can be used anywhere as the user needs to sit. Many chairless chairs or wearable-chairs have been invented over the years. Here, the focus is on the findings from the simulations and analyses performed to investigate the critical stress area in the design assembly as well as its factor of safety. The simulations included in this paper are motion analysis and stress analysis. The outcome of this investigation is that this design is be able to deliver its purpose if it were to be manufactured for safe use by the masses.
Review of Wire Arc Additive Manufacturing for 3D Metal Printing
International Journal of Automation Technology, 2019
Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic s... more Wire arc additive manufacturing (WAAM) is a crucial technique in the fabrication of 3D metallic structures. It is increasingly being used worldwide to reduce costs and time. Generally, AM technology is used to overcome the limitations of traditional subtractive manufacturing (SM) for fabricating large-scale components with lower buy-to-fly ratios. There are three heat sources commonly used in WAAM: metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW). MIG is easier and more convenient than TIG and PAW because it uses a continuous wire spool with the welding torch. Unlike MIG, tungsten inert gas welding (TIG) and plasma arc welding (PAW) need an external wire feed machine to supply the additive materials. WAAM is gaining popularity in the fabrication of 3D metal components, but the process is hard to control due to its inherent residual stress and distortion, which are generated by the high thermal input from its heat sources. Distortion and r...
Journal of Mechanical Engineering Research and Developments, 2018
3D printing or additive manufacturing (AM) is a technology that enables the fabrication of 3D dat... more 3D printing or additive manufacturing (AM) is a technology that enables the fabrication of 3D data by depositing a thin layer of material layer-by-layer until a final product is produced. Recently, the application of metal-based material has been increasingly utilized. However, the price is expensive and limited to certain applications only. Thus, it severely restricts access to the technology for small and medium enterprises. Realizing its potential, this research focuses on the design and development of a low -cost 3D metal printer. The basic construction, process, and operation to develop a low-cost 3D metal printer are presented along with the material costs, connection of electronic part, and illustration of metal inert gas (MIG) welding. In order to test the newly developed low-cost 3D metal printer's performance, the main parameters that influence the accuracy and quality of a metal product are tested. The 3D printed structure's accuracies are examined and compared to computer-aided design data (CAD) data. The cross-sectional area of the samples was captured using SEM to check for the bonding between inter layer. Based on the study, it was found that a relatively acceptable 3D printed metal structure can be produced from the newly developed low-cost 3D metal printer. Thus, while having explored the potential of using the developed solution, it also opens-up into the area of further investigation particularly in the precision of observed over desired.
An exploration of polymer adhesion on 3D printer bed
IOP Conference Series: Materials Science and Engineering, 2017
One of the problems in Fused Deposition Modelling (FDM) 3D Printing process is that the extruded ... more One of the problems in Fused Deposition Modelling (FDM) 3D Printing process is that the extruded plastic filament tends to shrink and warp from the printing platform. The purpose of this research is to explore the warping deformation problem in four aspects i.e. curling, pincushion effect, trapezoid deformation and blocked shrinkage that usually occur in the process. Epoxy resin based adhesive was applied onto the printing platform to reduce and eliminate the warping deformation. Afterwards, by applying the adhesive, the 3D printed models were measured their curling, pincushion, trapezoid and blocked shrinkage using laser scanner and metrology software. The result shows that the pincushion and trapezoid has low deformation compared to curling and blocked shrinkage. Blocked shrinkage effect shows the highest warping deformation value. In comparison of materials, PLA shows the best geometry result with low warping deformation value and the best surface finish.
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