Hybrid Prototypes to Assist Modeling Automotive Seats

The development of new modular seats is an important issue in the automotive industry. However, is very time consuming and costly. Virtual models and hybrid prototypes could accelerate the car seats development process. The hybrid prototypes are mainly manufactured by rapid prototyping with multi materials. The objective of this paper is to establish a methodology to develop innovative lightweight multi-functional, modular car seats to be used in Multi-Purpose Vehicles (MPV), by means of FEA simulation and rapid prototyping additive/subtractive technologies utilizing multi materials. A case study is presented to validate the developed methodology. The manufactured hybrid prototype’s reproduces the main functionalities of the MPV modular seat, namely its three key positions: normal, stored and table.Mechanical Engineerin

Electrostatic Levitation for Studies of Additive Manufactured Materials

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center is a unique facility for investigators studying high temperature materials. The laboratory boasts two levitators in which samples can be levitated, heated, melted, undercooled, and resolidified. Electrostatic levitation minimizes gravitational effects and allows materials to be studied without contact with a container or instrumentation. The lab also has a high temperature emissivity measurement system, which provides normal spectral and normal total emissivity measurements at use temperature. The ESL lab has been instrumental in many pioneering materials investigations of thermophysical properties, e.g., creep measurements, solidification, triggered nucleation, and emissivity at high temperatures. Research in the ESL lab has already led to the development of advanced high temperature materials for aerospace applications, coatings for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials processing is necessary for the study of their resulting materials properties. In addition, the modeling of the selective laser melting processes and its materials property predictions are also underway. Unfortunately, there is very little data for the properties of these materials, especially of the materials in the liquid state. Some method to measure thermophysical properties of additive manufacturing materials is necessary. The ESL lab is ideal for these studies. The lab can provide surface tension and viscosity of molten materials, density measurements, emissivity measurements, and even creep strength measurements. The ESL lab can also determine melting temperature, surface temperatures, and phase transition temperatures of additive manufactured materials. This presentation will provide background on the ESL lab and its capabilities, provide an approach to using the ESL in supporting the development and modeling of the selective laser melting process for metals, and provide an overview of the results to date

Towards Fully Additively-Manufactured Permanent Magnet Synchronous Machines: Opportunities and Challenges

With the growing interest in electrification and as hybrid and pure electric powertrains are adopted in more applications, electrical machine design is facing challenges in terms of meeting very demanding performance metrics for example high specific power, harsh environments, etc. This provides clear motivation to explore the impact of advanced materials and manufacturing on the performance of electrical machines. This paper provides an overview of additive manufacturing (AM) approaches that can be used for constructing permanent magnet (PM) machines, with a specific focus on additively-manufactured iron core, winding, insulation, PM as well as cooling systems. Since there has only been a few attempts so far to explore AM in electrical machines (especially when it comes to fully additively-manufactured machines), the benefits and challenges of AM have not been comprehensively understood. In this regard, this paper offers a detailed comparison of multiple multi-material AM methods, showing not only the possibility of fully additively-manufactured PM machines but also the potential significant improvements in their mechanical, electromagnetic and thermal properties. The paper will provide a comprehensive discussion of opportunities and challenges of AM in the context of electrical machines

Embedded fibre optic sensors within additive layer manufactured components

Smart materials with integrated sensing capabilities are now ubiquitous in many structures manufactured from composite materials and offer enhancement to the safety, reliability and efficiency of the resulting devices. This paper explores the application of embedded sensors to components manufactured using Additive Layer Manufacturing (ALM) technology. ALM offers the ability to create physical parts with little or no restriction in shape complexity. In this paper, optical fibre sensors incorporating fibre Bragg gratings (FBGs) were embedded inside a component made during a powder bed based layer-by-layer additive manufacturing process using a commercial EOS P730 system, where a laser was used to sinter the polymeric powder into a three dimensional component. The approach is based upon insertion of a ‘fibre-carrier’ component which replaced a removable ‘place-holder’ component during an interruption of the ALM build process. Tensile test specimens fabricated this way have been subjected to extended cyclic tensile loading trials at low strain levels of up to 475 µe. The test specimens demonstrated stable and reproducible responses over a period in excess of 720 days and 311,000 load cycles. Polyimide (PI) and acrylic (PMMA) jacketed fibres have been trialled and the resulting deformations of the component through internal stresses depending on the fibre jacket type are discussed.<br/

Analysis of the Machining Process of Titanium Ti6Al-4V Parts Manufactured by Wire Arc Additive Manufacturing (WAAM)

In the current days, the new range of machine tools allows the production of titanium alloy parts for the aeronautical sector through additive technologies. The quality of the materials produced is being studied extensively by the research community. This new manufacturing paradigm also opens important challenges such as the definition and analysis of the optimal strategies for finishing-oriented machining in this type of part. Researchers in both materials and manufacturing processes are making numerous advances in this field. This article discusses the analysis of the production and subsequent machining in the quality of TI6Al4V produced by Wire Arc Additive Manufacturing (WAAM), more specifically Plasma Arc Welding (PAW). The promising results observed make it a viable alternative to traditional manufacturing methods.This research was funded by the vice-counseling of technology, innovation and competitiveness of the Basque Government grant agreement kk-2019/00004 (PROCODA project)

Latest Developments in Industrial Hybrid Machine Tools that Combine Additive and Subtractive Operations

Hybrid machine tools combining additive and subtractive processes have arisen as a solution to increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations. Nevertheless, the idea of hybrid machines is relatively new and there is a notable lack of knowledge about the implications arisen from their in-practice use. Therefore, the main goal of the present paper is to fill the existing gap, giving an insight into the current advancements and pending tasks of hybrid machines both from an academic and industrial perspective. To that end, the technical-economical potentials and challenges emerging from their use are identified and critically discussed. In addition, the current situation and future perspectives of hybrid machines from the point of view of process planning, monitoring, and inspection are analyzed. On the one hand, it is found that hybrid machines enable a more efficient use of the resources available, as well as the production of previously unattainable complex parts. On the other hand, it is concluded that there are still some technological challenges derived from the interaction of additive and subtractive processes to be overcome (e.g., process planning, decision planning, use of cutting fluids, and need for a post-processing) before a full implantation of hybrid machines is fulfilledSpecial thanks are addressed to the Industry and Competitiveness Spanish Ministry for the support on the DPI2016-79889-R INTEGRADDI project and to the PARADDISE project H2020-IND-CE-2016-17/H2020-FOF-2016 of the European Union's Horizon 2020 research and innovation program

Biomechanical analysis of a cranial Patient Specific Implant on the interface with the bone using the Finite Element Method

- New advance technologies based on reverse engineering , design and additive manufacturing, have expanded design capabilities for biomedical applications to include Patient Specific Implants (PSI). This change in design paradigms needs advanced tools to assess the mechanical performance of the product, and simulate the impact on the patient. In this work, we perform a structural analysis on the interface of a cranial PSI under static loading conditions. Based on those simulations, we have identified the regions with high stress and strain and checked the failure criteria both in the implant and the skull. We evaluate the quality of the design of the implant and determine their response given different materials, in order to ensure optimality of the final product to be manufactured

Investigating the thermal stability of 1-3 piezoelectric composite transducers by varying the thermal conductivity and glass transition temperature of the polymeric filler material

The thermal behaviour of a number of 1-3 piezoelectric composite transducers is discussed. In particular, devices manufactured from a polymer filler with a relatively high glass to rubber transition temperature (T-g), and from polymer systems with increased thermal conductivity, are evaluated. The mechanical properties of the various filler materials were obtained via ultrasonic measurements, with the thermal properties extracted using dynamic mechanical thermal analysis (dmta), differential scanning calorimetry (dsc) and laserflash studies. A range of ultrasonic transducers were then constructed and their thermal stability studied using a combination of impedance analysis and laser surface displacement measurement

Experimental analysis of manufacturing parameters’ effect on the flexural properties of wood-PLA composite parts built through FFF

This paper aims to determine the flexural stiffness and strength of a composite made of a polylactic acid reinforced with wood particles, named commercially as Timberfill, manufactured through fused filament fabrication (FFF). The influence of four factors (layer height, nozzle diameter, fill density, and printing velocity) is studied through an L27Taguchi orthogonal array. The response variables used as output results for an analysis of variance are obtained from a set of four-point bending tests. Results show that the layer height is the most influential parameter on flexural strength, followed by nozzle diameter and infill density, whereas the printing velocity has no significant influence. Ultimately, an optimal parameter set that maximizes the material’s flexural strength is found by combining a 0.2-mm layer height, 0.7-mm nozzle diameter, 75% fill density, and 35-mm/s velocity. The highest flexural resistance achieved experimentally is 47.26 MPa. The statistical results are supported with microscopic photographs of fracture sections, and validated by comparing them with previous studies performed on non-reinforced PLA material, proving that the introduction of wood fibers in PLA matrix reduces the resistance of raw PLA by hindering the cohesion between filaments and generating voids inside it. Lastly, five solid Timberfill specimens manufactured by injection molding were also tested to compare their strength with the additive manufactured samples. Results prove that treating the wood-PLA through additive manufacturing results in an improvement of its resistance and elastic properties, being the Young’s module almost 25% lower than the injected material.Preprin