The Place of 3D Printing in the Manufacturing and Operational Process Based on the Industry 4.0 Structure

The article presents the place of 3D printing in the manufacturing and operational process. It analyzes selected incremental technologies in the product life cycle. It describes selected processes for testing the properties of materials used in 3D printing, including accelerated aging tests and simulation of operating conditions. Areas of application of 3D printing were defined, starting from design and prototype development through manufacturing of technological tools and finally finished products. Design criteria of additivelymanufactured elements in relation to the exploitation process are discussed. A methodology for the development of 3D-CAD models of manufactured elements, software processing of data and data storage format for manufacturing products and spare parts is presented. The assumptions of repair procedures based on the production of spare parts by means of 3D printing in relation to data circulation compatible with the idea of Industry 4.0 structure have been adopted

Zastosowanie materiałów polimerowych do otrzymywania przekładni zębatych o zarysie ewolwentowym i sinusoidalnym

In the article research related to the increasing in the scope of application of additive technologies in the construction of machines for the production of gears with involute and sinusoidal profile from polymeric materials was presented. The designed original research stand and with its use carried out a series of preliminary fatigue tests of the obtained polymer gears with an involute and sinusoidal profile was show. The tested gears were obtained in the technology of rapid prototyping by the FFF (Fused Filament Fabrication) method from polymer composites obtained in the form of an ABS (acrylonitrile/butadiene/styrene) – based filament. Based on the results obtained, it was noticed that the temperature in the meshing zone of the gears with involute profiles is higher than for sinusoidal profiles, regardless of the type of composite from which the gears were made. It should also be noted that in the range of nominal load, the sound intensity level of the meshing zone is also lower for gears with a sinusoidal profile than for gears with an involute profile. Based on the tests carried out, an increase in sound intensity was noticed in the case of gears obtained from selected composites (Table 2) compared to the gear obtained from unfilled ABS. However, in the case of gears obtained from the tested composite materials, we observe a decrease in the gear operating temperature (Table 2). The most favorable results of these tests were obtained for gears with a sinusoidal profile obtained from ABS + P2 composite, which show the lowest operating temperature of the gear. It should also be mentioned that slightly worse results were obtained for involute gears.Przedstawiono badania związane ze zwiększeniem zakresu zastosowania technologii przyrostowych w budowie maszyn do otrzymywania przekładni zębatych o zarysie ewolwentowym i sinusoidalnym, które mogą być wytwarzane z materiałów polimerowych z wykorzystaniem technologii przyrostowych. Opisano zaprojektowane autorskie stanowisko badawcze, na którym przeprowadzono serię wstępnych badań zmęczeniowych przekładni zębatych o zarysie ewolwentowym i sinusoidalnym, otrzymanych z materiałów polimerowych. Badane przekładnie zębate wytworzono za pomocą technologii szybkiego prototypowania (FFF) z kompozytów polimerowych na osnowie z ABS (akrylonitryl/butadien/styren) w postaci filamentów. Na podstawie uzyskanych wyników badań stwierdzono, że temperatura kół o zarysie ewolwentowym w strefie zazębiania jest wyższa niż kół o zarysie sinusoidalnym, niezależnie od rodzaju kompozytu, z którego wykonano koła zębate, a w zakresie obciążenia nominalnego także poziom natężenia dźwięku emitowanego w strefie zazębiania jest wyższy w wypadku kół o zarysie ewolwentowym niż kół o zarysie sinusoidalnym. Zaobserwowano nieznaczny wzrost natężenia generowanego dźwięku w wypadku przekładni zębatych otrzymanych z wytypowanych kompozytów (tabela 2) w porównaniu z natężeniem dźwięku generowanego przez przekładnię wykonaną z nienapełnionego ABS. W odniesieniu do przekładni otrzymanych z badanych materiałów kompozytowych zaobserwowano spadek temperatury pracy przekładni (tabela 2). Najniższą temperaturę pracy wykazywała przekładnia kół zębatych o zarysie sinusoidalnym otrzymana z kompozytu ABS + P2, a tylko nieznacznie gorsze wyniki uzyskano w wypadku przekładni kół zębatych o zarysie ewolwentowym

Polymer Composites Based on Polycarbonate/Acrylonitrile-Butadiene-Styrene Used in Rapid Prototyping Technology

As part of this work, polymer composites based on polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS) were obtained and used in 3D printing technology, particularly Melted Extrusion Modeling (MEM) technology. The influence of selected fillers on the properties of the obtained composites was investigated. For this purpose, modified fillers such as silica modified with alumina, bentonite modified with a quaternary ammonium salt, and hybrid lignin/silicon dioxide filler were introduced into the PC/ABS matrix. In the first part of this work, polymer blends and their composites containing 1.5–3 wt. of the filler were used to obtain the filament using the proprietary technological line. Moldings for testing the performance properties were obtained using additive manufacturing techniques and injection molding. In the subsequent part of this work, rheological properties (mass flow rate (MFR) and viscosity curves) and mechanical properties (Rockwell hardness and static tensile strength with Young’s modulus) were examined. The structures of the obtained composites were also determined by scanning electron microscopy (SEM/EDS). The obtained results confirmed the results obtained from a wide-angle X-ray scattering analysis (WAXS). In turn, the physicochemical properties were characterized on the basis of the results of tests using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). Based on the obtained results, it was found that the introduced modified additives had a significant impact on the processing and functional properties of the tested composites.</jats:p

Hybrid Polymer Composites Based on Polystyrene (PS) Used in the Melted and Extruded Manufacturing Technology

As part of the work, innovative hybrid polymer composites dedicated to rapid prototyping, especially for 3D printing with the melted and extruded manufacturing (MEM) technique, were developed. For this purpose, the influence of modified fillers, such as alumina-modified silica, bentonite modified with quaternary ammonium salt, and lignin/silicon dioxide hybrid filler, on the functional properties of polystyrene-based composites was investigated. The introduced additives were selected to improve the processing properties of polystyrene (PS), in particular its thermal stability, while maintaining good mechanical properties. In the first part of the work, using the proprietary technological line, filaments from unfilled PS and its composites were obtained, which contain modified fillers in the amount of 1.5% to 3.0% by weight. Samples for testing functional properties were obtained by 3D printing in MEM technology and injection technique. The rheological properties&mdash;mass melt flow rate (MFR), viscosity, and mechanical properties&mdash;are presented in the further part of the work. The size and the respective dispersion in the polystyrene polymer matrix of the fillers used were determined by scanning electron microscopy with energy dispersion spectroscopy (SEM/EDS). The correct dispersion of additives in PS was also confirmed by wide-angle X-ray analysis (WAXS). A significant improvement in the thermal stability of the obtained composites after the introduction of fillers into the polymer matrix was confirmed on the basis of thermogravimetric analysis (TGA). The remaining tests of physicochemical properties, differential scanning calorimetry (DSC), and infrared spectroscopy with Fourier transform (FT-IR) allowed us to state no significant changes in relation to polystyrene. The obtained test results allowed us to conclude that the amount and type of fillers used in the PS polymer matrix significantly affect the performance properties of the tested hybrid composites. The composites obtained as part of the work can be successfully used in rapid prototyping technologies, especially for the production of details originally designed from PS, which are required to have higher thermal stability than is guaranteed only by the polymer matrix