The world is proceeding towards mass customization due to the increasing individual demands of end-users. Consequently, manufacturing systems must show adaptability to meet the changing consumer needs. As a result, specific methods with certain tools and strategies should be brought into practice to globalize the mass customization. Mass customization facilitates in manufacturing products, specific to customers, as per individual needs but traditional manufacturing faces severe challenges to implement mass customization due to the traditional approach of design for manufacturing. Alternatively, additive manufacturing has proved to be the best technology to provide mass customization solutions with even more complex and customer specific products. Moreover, design for additive manufacturing (DFAM) parts can be produced with short lead time with comparable strength to those produced with traditional manufacturing approaches. Thus, additive manufacturing can be more diverse and applicable towards mass customization solutions. This work is presented to evaluate different mass reduction strategies by combined effects of topology optimization and infill density for extrusion based additive manufacturing and study their strength with respect to their manufacturing time (cost). The study is carried out on bio-degradable PLA, manufactured using Fused Deposition Modeling (FDM). The experimental analysis is carried out with standard compression and tensile specimens for 5 levels of mass retained i.e. 100%, 85%, 70%, 50% and 30%. Mass reduction is done by the combination of topology optimization and infill density, using a proportion of 50:50, 33:67 and 66:34. Therefore, 5 different levels for both compression and tensile specimens and 3 levels of crosshead speed (0.25, 2.5 and 25 mm/min), 78 specimens were tested. The additive manufacturing of these specimens was performed on Creality Ender-3 FDM machine with preset process parameters. As a result of the experimental analysis, the mechanical properties such as young’s modulus, yield strength, maximum stress induced, and cost-coefficient are verified. The results obtained from experimental analysis support the fact that all the parameters with varying levels effect the components’ strength and cost-coefficient. Consequently, we can have an acceptable trade-off between the strength and manufacturing lead time/material consumed and hence cost of manufacturing.
Il panorama industriale sta procedendo verso la personalizzazione di massa a causa delle crescenti esigenze individuali degli utenti finali. Perciò, da un lato, i sistemi di produzione devono adattarsi per soddisfare le mutevoli esigenze dei consumatori. Dall’altro lato, è necessario sfruttare metodi e strategie specifiche per globalizzare la personalizzazione di massa. Infatti, quest’ultima garantisce la realizzazione di prodotti su misura per il cliente. Tuttavia, a causa dell'approccio tradizionale nella progettazione dei processi di produzione, diverse numerose sfide pratiche devono essere superate per implementare la personalizzazione di massa. In questa prospettiva, la manifattura additiva si è dimostrata la migliore tecnologia alternativa per fornire soluzioni di personalizzazione di massa con prodotti caratterizzati da geometria complessa e specifica per il cliente. Inoltre, le parti di realizzate tramite manifattura additiva possono essere prodotte con tempi di consegna brevi e con proprietà meccaniche paragonabili a quelle prodotte con approcci tradizionali. Pertanto, la manifattura additiva rappresenta una valida alternativa nella produzione di massa di parti personalizzabili. L’obiettivo di questo lavoro è la valutazione di diverse strategie di alleggerimento della massa, quali ottimizzazione topologica e densità di riempimento, per la manifattura additiva basata sull'estrusione e lo studio dei possibili vantaggi in termini di tempo di produzione (costo). Lo studio è condotto su PLA biodegradabile, prodotto utilizzando la tecnologia Fused Deposition Modeling (FDM). Per la sperimentazione sono stati realizzati provini standard di compressione e trazione per 5 livelli di massa trattenuta, ovvero 100%, 85%, 70%, 50% e 30%. L’alleggerimento della massa è stato ottenuto combinando l'ottimizzazione topologica e la densità di riempimento, utilizzando una proporzione di 50:50, 33:67 e 66:34. Pertanto, utilizzando 5 diversi livelli per i provini di compressione e trazione e 3 livelli di velocità della traversa (0,25, 2,5 e 25 mm / min), sono stati realizzati e analizzati 78 provini. Per l’attività sperimentale è stata usata un sistema di manifattura additiva basato sull’estrusione (Creality Ender-3 FDM) con parametri di processo preimpostati. Come risultato dell'analisi sperimentale sono state studiate le proprietà meccaniche come il modulo di Young, la resistenza allo snervamento, lo stress massimo indotto e il coefficiente di costo. I risultati ottenuti dall'analisi sperimentale implicano che tutti le variabili influenzano la resistenza dei componenti e il coefficiente di costo. Pertanto, è possibile un compromesso accettabile tra la resistenza meccanica e il lead time di produzione / materiale consumato e quindi il costo di produzione.
Effects of topology optimisation and infill density on mechanical properties of extrusion-based additive manufacturing samples
Iqbal, Hambal
2020/2021
Abstract
The world is proceeding towards mass customization due to the increasing individual demands of end-users. Consequently, manufacturing systems must show adaptability to meet the changing consumer needs. As a result, specific methods with certain tools and strategies should be brought into practice to globalize the mass customization. Mass customization facilitates in manufacturing products, specific to customers, as per individual needs but traditional manufacturing faces severe challenges to implement mass customization due to the traditional approach of design for manufacturing. Alternatively, additive manufacturing has proved to be the best technology to provide mass customization solutions with even more complex and customer specific products. Moreover, design for additive manufacturing (DFAM) parts can be produced with short lead time with comparable strength to those produced with traditional manufacturing approaches. Thus, additive manufacturing can be more diverse and applicable towards mass customization solutions. This work is presented to evaluate different mass reduction strategies by combined effects of topology optimization and infill density for extrusion based additive manufacturing and study their strength with respect to their manufacturing time (cost). The study is carried out on bio-degradable PLA, manufactured using Fused Deposition Modeling (FDM). The experimental analysis is carried out with standard compression and tensile specimens for 5 levels of mass retained i.e. 100%, 85%, 70%, 50% and 30%. Mass reduction is done by the combination of topology optimization and infill density, using a proportion of 50:50, 33:67 and 66:34. Therefore, 5 different levels for both compression and tensile specimens and 3 levels of crosshead speed (0.25, 2.5 and 25 mm/min), 78 specimens were tested. The additive manufacturing of these specimens was performed on Creality Ender-3 FDM machine with preset process parameters. As a result of the experimental analysis, the mechanical properties such as young’s modulus, yield strength, maximum stress induced, and cost-coefficient are verified. The results obtained from experimental analysis support the fact that all the parameters with varying levels effect the components’ strength and cost-coefficient. Consequently, we can have an acceptable trade-off between the strength and manufacturing lead time/material consumed and hence cost of manufacturing.| File | Dimensione | Formato | |
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Hambal's thesis.pdf
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https://hdl.handle.net/10589/174280