Overlapping optimization of hybrid deposited and micro-rolling additive manufacturing

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Xushan Zhao ◽  
Yuanxun Wang ◽  
Haiou Zhang ◽  
Runsheng Li ◽  
Xi Chen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Rolling Process ◽  
Weld Bead ◽  
Content Type ◽  
Profile Fitting ◽  
Overlapping Coefficient ◽  
Surface Flatness ◽  
The Mathematical Model ◽  
Bead Profile

Purpose This paper aims to summarize the influence law of hybrid deposited and micro-rolling (HDMR) technology on the bead morphology and overlapping coefficient. A better bead topology positively supports the overlapping deposited in multi-beads between layers while actively assisting the subsequent layer's deposition in the wire and arc additive manufacturing (WAAM). Hybrid-deposited and micro-rolling (HDMR) additive manufacturing (AM) technology can smooth the weld bead for improved surface quality. However, the micro-rolling process will change the weld bead profile fitting curve to affect the overlapping coefficient. Design/methodology/approach Weld bead contours for WAAM and HDMR were extracted using line lasers. A comparison of bead profile curves was conducted to determine the influence law of micro-zone rolling on the welding bead contour and fitting curve. Aiming at the optimized overlapping coefficient of weld bead in HDMR AM, the optimal HDMR overlapping coefficient curve was proposed which varies with the reduction based on the best surface flatness. The mathematical model for overlapping in HDMR was checked by comparing the HDMR weld bead contours under different rolling reductions. Findings A fitting function of the bead forming by HDMR AM was proposed based on the law of conservation of mass. The change rule of the HDMR weld bead overlapping spacing with the degree of weld bead rolling reduction was generated using the flat-top transition calculation for this model. Considering the damming-up impact of the first bead, the overlapping coefficient was examined for its effect on layer surface flatness. Originality/value Using the predicted overlapping model, the optimal overlapping coefficients for different rolling reductions can be achieved without experiments. These conclusions can encourage the development of HDMR technology.

Investigation, modeling and optimization of abnormal areas of weld beads in wire and arc additive manufacturing

2020 ◽  
Vol 26 (7) ◽  
pp. 1183-1195
Author(s):  
Shangyong Tang ◽  
Guilan Wang ◽  
Cheng Huang ◽  
Runsheng Li ◽  
Siyu Zhou ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Second Order ◽  
Weld Bead ◽  
Welding Parameters ◽  
Forming Process ◽  
Content Type ◽  
Modeling And Optimization ◽  
Modeling Methods ◽  
The Relationship

Purpose The modeling and optimization of a weld bead in the middle of the weld are often simple, as the forming process is dynamically balanced. However, the arc striking (AS) and arc extinguishing (AE) areas of weld beads are generally abnormal because the dynamic processes at these areas are unstable. The purpose of this paper is to investigate the abnormal areas of the weld bead with optimization modeling methods in wire and arc additive manufacturing (WAAM). Design/methodology/approach A burning-back method was proposed to fill the slanted plane in the AE area. To optimize the welding parameters and obtain the optimal design, a response surface methodology was proposed to build the relationships between the input parameters and response variables. Findings The proposed burning-back method could fill the slanted plane in the AE area. Second-order models of abnormal areas were developed and the optimization effects were analyzed. The experimental results indicated that the relationship models at both ends were applicable and preferable for the optimization of weld beads. Originality/value In this paper, a burning-back method was proposed to optimize the slanted plane in the AE area. Second-order models of abnormal areas were established. The methods and models were preferable in the optimization of the abnormal areas in WAAM.

Episodic supply chains at times of disruption

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Christina Öberg
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
Supply Chains ◽  
Design Methodology ◽  
Secondary Data ◽  
Transformational Change ◽  
Content Type ◽  
Metal Additive Manufacturing ◽  
Contemporary Technology ◽  
Metal Additive

Purpose Additive manufacturing has been described as converting supply chains into demand chains. By focusing on metal additive manufacturing as a contemporary technology causing ongoing disruption to the supply chain, the purpose of this paper is to describe and discuss how incumbent firms act during an ongoing, transformational disruption of their supply chain. Design/methodology/approach Interviews and secondary data, along with seminars attracting approximately 600 individuals operating in metal additive manufacturing, form the empirical basis for this paper. Findings The findings of this paper indicate how disruption occurs at multiple positions in the supply chain. Episodic positions as conceptualised in this paper refer to how parties challenged by disruption attempt to reach normality while speeding the transformational disruption. Originality/value This paper contributes to previous research by theorising about episodic positions in light of a supply chain disruption. The empirical data are unique in how they capture supply chain change at the time of disruption and illustrate disruptive, transformational change to supply chains. The paper interlinks research on disruption from the innovation and supply chain literature, with contributions to both.

3D printing technology in musical instrument research: reviewing the potential

2018 ◽  
Vol 24 (9) ◽  
pp. 1511-1523 ◽  
Author(s):  
Antreas Kantaros ◽  
Olaf Diegel
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Musical Instrument ◽  
Musical Instruments ◽  
Wind Instruments ◽  
Content Type ◽  
New Class ◽  
History Of ◽  
New Applications ◽  
Practical Implications

Purpose This paper aims to discuss additive manufacturing (AM) in the context of applications for musical instruments. It examines the main AM technologies used in musical instruments, goes through a history of musical applications of AM and raises the questions about the application of AM to create completely new wind instruments that would be impossible to produce with conventional manufacturing. Design/methodology/approach A literature research is presented which covers a historical application of AM to musical instruments and hypothesizes on some potential new applications. Findings AM has found extensive application to create conventional musical instruments with unique aesthetics designs. It’s true potential to create entirely new sounds, however, remains largely untapped. Research limitations/implications More research is needed to truly assess the potential of additive manufacturing to create entirely new sounds for musical instrument. Practical implications The application of AM in music could herald an entirely new class of musical instruments with unique sounds. Originality/value This study highlights musical instruments as an unusual application of AM. It highlights the potential of AM to create entirely new sounds, which could create a whole new class of musical instruments.

Smooth geometry generation in additive manufacturing file format: problem study and new formulation

2017 ◽  
Vol 23 (1) ◽  
pp. 34-43 ◽  
Author(s):  
Kai-Ming Yu ◽  
Yu Wang ◽  
Charlie C.L. Wang
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Hermite Interpolation ◽  
File Format ◽  
Opposite Edge ◽  
Standard Specification ◽  
Content Type ◽  
New Formulation ◽  
Boundary Curves ◽  
Boolean Sum

Purpose In the newly released ASTM standard specification for additive manufacturing file (AMF) format – version 1.1 – Hermite curve-based interpolation is used to refine input triangles to generate denser mesh with smoother geometry. This paper aims to study the problems of constructing smooth geometry based on Hermite interpolation on curves and proposes a solution to overcome these problems. Design/methodology/approach A formulation using triangular Bézier patch is proposed to generate smooth geometry from input polygonal models. Different configurations on the boundary curves in the formulation are analyzed to further enrich this formulation. Findings The study shows that the formulation given in the AMF format (version 1.1) can lead to the problems of inconsistent normals and undefined end-tangents. Research limitations/implications The scheme has requirements on the input normals of a model, only C0 interpolation can be generated on those cases with less-proper input. Originality/value To overcome the problems of smooth geometry generation in the AMF format, the authors propose an enriched scheme for computing smooth geometry by using triangular Bézier patch. For the configurations with less-proper input, the authors adopt the Boolean sum and the Nielson’s point-opposite edge interpolation for triangular Coons patch to generate the smooth geometry as a C0 interpolant.

Barriers in adoption of additive manufacturing in medical sector supply chain

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Neha Choudhary ◽  
Anish Kumar ◽  
Varun Sharma ◽  
Pradeep Kumar
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Manufacturing Sector ◽  
Extensive Literature ◽  
Content Type ◽  
Potential Barriers ◽  
Organizational Barriers ◽  
Medical Sector ◽  
Network Process ◽  
And Training

PurposeAdditive manufacturing (AM) is expected to significantly transform the operations in manufacturing sector. It is also proposed to have optimistic applications in the medical supply chains (SC). However, its adoption in medical sector is faced with a range of barriers. Motivated by the need to establish an AM-based medical SC in a developing economy, the present paper analyses the potential barriers that would hinder the adoption of AM in medical SC.Design/methodology/approachBased on an extensive literature review and expert discussions, 12 significant barriers have been identified, which are analysed using an integrated interpretive structural modelling–analytical network process (ISM–ANP) methodology. An interrelationship between these barriers using ISM has been analysed to determine the driving-dependence power of these barriers using MICMAC (Matrice d' Impacts Croises-Multiplication Applique' e a' Classement) analysis. The barriers are then ranked using the ANP approach.FindingsIt has been focussed that the non-availability of a variety of materials, lack of education and training to designers and workers and production technology limitation are the most critical barriers. The results suggest that the managers should give greater significance to the technological and organizational barriers.Originality/valueAn approach to overcome these barriers can help the managers and organizations to develop successful AM-based SCs. The study is the first to identify and analyse the barriers for successful adoption of AM in medical SC context.

Maximizing design potential: investigating the effects of utilizing opportunistic and restrictive design for additive manufacturing in rapid response solutions

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Rohan Prabhu ◽  
Jordan Scott Masia ◽  
Joseph T. Berthel ◽  
Nicholas Alexander Meisel ◽  
Timothy W. Simpson
Keyword(s):  
Additive Manufacturing ◽  
Design Methodology ◽  
Linear Models ◽  
Design For Additive Manufacturing ◽  
Content Type ◽  
Manufacturing Efficiency ◽  
Material Usage ◽  
Build Time ◽  
Rapid Prototyping And Manufacturing ◽  
Design For Am

Purpose The COVID-19 pandemic has resulted in numerous innovative engineering design solutions, several of which leverage the rapid prototyping and manufacturing capabilities of additive manufacturing. This paper aims to study a subset of these solutions for their utilization of design for AM (DfAM) techniques and investigate the effects of DfAM utilization on the creativity and manufacturing efficiency of these solutions. Design/methodology/approach This study compiled 26 COVID-19-related solutions designed for AM spanning three categories: (1) face shields (N = 6), (2) face masks (N = 12) and (3) hands-free door openers (N = 8). These solutions were assessed for (1) DfAM utilization, (2) manufacturing efficiency and (3) creativity. The relationships between these assessments were then computed using generalized linear models to investigate the influence of DfAM utilization on manufacturing efficiency and creativity. Findings It is observed that (1) unique and original designs scored lower in their AM suitability, (2) solutions with higher complexity scored higher on usefulness and overall creativity and (3) solutions with higher complexity had higher build cost, build time and material usage. These findings highlight the need to account for both opportunistic and restrictive DfAM when evaluating solutions designed for AM. Balancing the two DfAM perspectives can support the development of solutions that are creative and consume fewer build resources. Originality/value DfAM evaluation tools primarily focus on AM limitations to help designers avoid build failures. This paper proposes the need to assess designs for both, their opportunistic and restrictive DfAM utilization to appropriately assess the manufacturing efficiency of designs and to realize the creative potential of adopting AM.

Multiaxis wire and arc additive manufacturing for overhangs based on conical substrates

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Fusheng Dai ◽  
Shuaifeng Zhang ◽  
Runsheng Li ◽  
Haiou Zhang
Keyword(s):  
Principal Component Analysis ◽  
Additive Manufacturing ◽  
Design Methodology ◽  
Principal Component ◽  
Deposition Process ◽  
Content Type ◽  
Melt Pool ◽  
Planning Approach ◽  
Intelligent Approach ◽  
Supporting Structures

Purpose This paper aims to present a series of approaches for three-related issues in multiaxis in wire and arc additive manufacturing (WAAM) as follows: how to achieve a stable and robust deposition process and maintain uniform growth of the part; how to maintain consistent formation of a melt pool on the surface of the workpiece; and how to fabricate an overhanging structure without supports. Design/methodology/approach The principal component analysis-based path planning approach is proposed to compute the best scanning directions of slicing contours for the generation of filling paths, including zigzag paths and parallel skeleton paths. These printing paths have been experimented with in WAAM. To maintain consistent formation of a melt pool at overhanging regions, the authors introduce definitions for the overhanging point, overhanging distance and overhanging vector, with which the authors can compute and optimize the multiaxis motion. A novel fabricating strategy of depositing the overhanging segments as a support for the deposition of filling paths is presented. Findings The second principal component of a planar contour is a reasonable scanning direction to generate zigzag filling paths and parallel skeleton filling paths. The overhanging regions of a printing layer can be supported by pre-deposition of overhanging segments. Large overhangs can be successfully fabricated by the multiaxis WAAM process without supporting structures. Originality/value An intelligent approach of generating zigzag printing paths and parallel skeleton printing paths. Optimizations of depositing zigzag paths and parallel skeleton paths. Applications of overhanging point overhanging distance and overhanging vector for multiaxis motion planning. A novel fabricating strategy of depositing the overhanging segments as a support for the deposition of filling paths.

On the verge of disruption: rethinking position and role – the case of additive manufacturing

2019 ◽  
Vol 34 (5) ◽  
pp. 1093-1105 ◽  
Author(s):  
Christina Öberg ◽  
Tawfiq Shams
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Design Methodology ◽  
Secondary Data ◽  
Point Of View ◽  
Disruptive Technology ◽  
Content Type ◽  
Business Cases ◽  
Metal 3D Printing

Purpose With the overarching idea of disruptive technology and its effects on business, this paper focuses on how companies strategically consider meeting the challenge of a disruptive technology such as additive manufacturing. The purpose of this paper is to describe and discuss changes in positions and roles related to the implementation of a disruptive technology. Design/methodology/approach Additive manufacturing could be expected to have different consequences for parties based on their current supply chain positions. The paper therefore investigates companies’ strategies related to various supply chain positions and does so by departing from a position and role point of view. Three business cases related to metal 3D printing - illustrating sub-suppliers, manufacturers and logistics firms - describe as many strategies. Data for the cases were collected through meetings, interviews, seminars and secondary data focusing on both current business activities related to additive manufacturing and scenarios for the future. Findings The companies attempted to defend their current positions, leading to new roles for them. This disconnects the change of roles from that of positions. The changed roles indicate that all parties, regardless of supply chain positions, would move into competing producing roles, thereby indicating how a disruptive technology may disrupt network structures based on companies’ attempts to defend their positions. Originality/value The paper contributes to previous research by reporting a disconnect between positions and roles among firms when disruption takes place. The paper further denotes how the investigated firms largely disregarded network consequences at the disruptive stage, caused by the introduction of additive manufacturing. The paper also contributes to research on additive manufacturing by including a business dimension and linking this to positions and roles.

Temperature distribution simulations during electron beam freeform fabrication process based on the fully threaded tree

2019 ◽  
Vol 25 (6) ◽  
pp. 989-997
Author(s):  
Yajun Yin ◽  
Wei Duan ◽  
Kai Wu ◽  
Yangdong Li ◽  
Jianxin Zhou ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Temperature Distribution ◽  
Design Methodology ◽  
Content Type ◽  
Freeform Fabrication ◽  
Simulation Based ◽  
Simulation Results

Purpose The purpose of this study is to simulate the temperature distribution during an electron beam freeform fabrication (EBF3) process based on a fully threaded tree (FTT) technique in various scales and to analyze the temperature variation with time in different regions of the part. Design/methodology/approach This study presented a revised model for the temperature simulation in the EBF3 process. The FTT technique was then adopted as an adaptive grid strategy in the simulation. Based on the simulation results, an analysis regarding the temperature distribution of a circular deposit and substrate was performed. Findings The FTT technique was successfully adopted in the simulation of the temperature field during the EBF3 process. The temperature bands and oscillating temperature curves appeared in the deposit and substrate. Originality/value The FTT technique was introduced into the numerical simulation of an additive manufacturing process. The efficiency of the process was improved, and the FTT technique was convenient for the 3D simulations and multi-pass deposits.

A deterministic inventory model in reverse supply chain

2019 ◽  
Vol 15 (1) ◽  
pp. 318-338 ◽  
Author(s):  
Sasmita Mohapatra ◽  
Ajay Kumar Behera ◽  
Rabindra Mahapatra ◽  
Harish Das
Keyword(s):  
Design Methodology ◽  
Current Model ◽  
Environmental Damage ◽  
Reverse Supply Chain ◽  
Retail Outlet ◽  
Present Value ◽  
Content Type ◽  
Unique Model ◽  
The Cost ◽  
The Mathematical Model

Purpose The purpose of this paper is to present a unique model for the production–recycling–reuse of aluminium refreshment cans. It is presumed that disposed-off 250-ml aluminium cans are collected from the retail outlet. The cans are thereafter arranged into non-tainted and tainted categories. Design/methodology/approach The current model considers all the factors, i.e. producing, recycling and remanufacturing, whereas the previous models provide emphasis only one factor. Six procedures were considered in the improvement of the mathematical model. Findings In this paper, a recycling–reuse model that remanufactures non-tainted aluminium beverage cans and uses regrind from damaged non-tainted aluminium beverage cans mixed with parent aluminium material in the production of new cans was developed and analysed to reduce the amount of aluminium beverage cans that are disposed off in a scrapyard. The model is assumed to have no shortcomings, and the different percentages regarding the classes of cans are taken to be deterministic. Originality/value The model incorporates several unique aspects, including accounting for the cost of land use and associated environmental damage through the calculation of a present value that is charged to the manufacturer.

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