Optimising surface roughness and density in titanium fabrication via laser powder bed fusion

The Ti6Al4V alloy has many advantages, such as being lightweight, formal, and resistant to corrosion. This makes it highly desirable for various applications, especially in the aerospace industry. Laser Powder Bed Fusion (LPBF) is a technique that allows for the production of detailed and unique parts with great flexibility in design. However, there are challenges when it comes to achieving high-quality surfaces and porosity formation in the material, which limits the wider use of LPBF. To tackle these challenges, this study uses statistical techniques called Design of Experiments (DoE) and Analysis of Variance (ANOVA) to investigate and optimise the process parameters of LPBF for making Ti6Al4V components with improved density and surface finish. The parameters examined in this study are laser power, laser scan speed, and hatch space. The optimisation study results show that using specific laser settings, like a laser power of 175 W, a laser scan speed of 1914 mm/s, and a hatch space of 53 µm, produces Ti6Al4V parts with a high relative density of 99.54% and low top and side surface roughness of 2.6 µm and 4.3 µm, respectively. This promising outcome demonstrates the practicality of optimising Ti6Al4V and other metal materials for a wide range of applications, thereby overcoming existing limitations and further expanding the potential of LPBF while minimising inherent process issues

Hybrid finite element–smoothed particle hydrodynamics modelling for optimizing cutting parameters in CFRP composites

Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool’s round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques

Multi stages toolpath optimisation of single point incremental forming process

Single point incremental forming (SPIF) is a flexible technology that can form a wide range of sheet metal products without the need for using punch and die sets. As a relatively cheap and die-less process, this technology is preferable for small and medium customised production. However, the SPIF technology has drawbacks, such as the geometrical inaccuracy and the thickness uniformity of the shaped part. This research aims to optimise the formed part geometric accuracy and reduce the processing time of a two-stage forming strategy of SPIF. Finite element analysis (FEA) was initially used and validated using experimental literature data. Furthermore, the design of experiments (DoE) statistical approach was used to optimise the proposed two-stage SPIF technique. Mass scaling technique was applied during the finite element analysis to minimise the computational time. The results showed that the step size during forming stage two have significantly affected the geometrical accuracy of the part, whereas the forming depth during stage one was insignificant to the part quality. It was also revealed that the geometrical improvement had taken place along the base and the wall regions. However, the areas near the clamp system showed minor improvements. The optimised two-stage strategy had successfully decreased both the geometrical inaccuracy and processing time. After optimisation, the average values of the geometrical deviation and forming time were reduced by 25% and 55.56%, respectively

Designing lightweight 3D-printable bioinspired structures for enhanced compression and energy absorption properties

Recent progress in additive manufacturing, also known as 3D printing, has offered several benefits, including high geometrical freedom and the ability to create bioinspired structures with intricate details. Mantis shrimp can scrape the shells of prey molluscs with its hammer-shaped stick, while beetles have highly adapted forewings that are lightweight, tough, and strong. This paper introduces a design approach for bioinspired lattice structures by mimicking the internal microstructures of a beetle’s forewing, a mantis shrimp’s shell, and a mantis shrimp’s dactyl club, with improved mechanical properties. Finite element analysis (FEA) and experimental characterisation of 3D printed polylactic acid (PLA) samples with bioinspired structures were performed to determine their compression and impact properties. The results showed that designing a bioinspired lattice with unit cells parallel to the load direction improved quasi-static compressive performance, among other lattice structures. The gyroid honeycomb lattice design of the insect forewings and mantis shrimp dactyl clubs outperformed the gyroid honeycomb design of the mantis shrimp shell, with improvements in ultimate mechanical strength, Young’s modulus, and drop weight impact. On the other hand, hybrid designs created by merging two different designs reduced bending deformation to control collapse during drop weight impact. This work holds promise for the development of bioinspired lattices employing designs with improved properties, which can have potential implications for lightweight high-performance applications

Chip formation and orthogonal cutting optimisation of unidirectional carbon fibre composites

This study presents a thorough experimental investigation utilising the design of experiments and analysis of variance (ANOVA) to examine the impact of machining process parameters on chip formation mechanisms, machining forces, workpiece surface integrity, and damage resulting from the orthogonal cutting of unidirectional CFRP. The study identified the mechanisms behind chip formation and found it to significantly impact the workpiece orientation of fibre and the tool’s cutting angle, resulting in increased fibre bounceback at larger fibre orientation angles and when using smaller rake angle tools. Increasing the depth of cut and fibre orientation angle results in an increased damage depth, while using higher rake angles reduces it. An analytical model based on response surface analysis for predicting machining forces, damage, surface roughness, and bounceback was also developed. The ANOVA results indicate that fibre orientation is the most significant factor in machining CFRP, while cutting speed is insignificant. Increasing fibre orientation angle and depth leads to deeper damage, while larger tool rake angles re-duce damage. Machining workpieces with 0° fibre orientation angle results in the least subsurface damage, and surface roughness is unaffected by the tool rake angle for fibre orientations between 0° to 90° but worsens for angles greater than 90°. Optimisation of cutting parameters were subsequently optimised to improve machined workpiece surface quality and reduce forces. The experimental results showed that negative rake angle and cutting at moderately low speeds (366 mm/min) is the optimal conditions for machining laminates with a fibre angle of θ = 45°. On the other hand, for composite materials with fibre angles of θ = 90° and θ = 135°, it is recommended to use a high positive rake angle and cutting speeds

Investigation and performance analysis of solar still with energy storage materials: An energy- exergy efficiency analysis

Researchers have attempted different Energy storage materials (ESM) in solar stills (SS) to improve distillate yield. In this experimental work, an attempt was made to increase the distillate yield & efficiency of SS, using good absorbing and heat transfer capacity of ESM. A comparison was made between a conventional solar still (CSS) and a solar still with energy storage materials (SSWESM) in this experiment. Different energy storage materials like black color glass ball (BCGB), black granite (BG) and white marble stone (WMS) were used in equal quantity during experimental work. CSS and SSWESM had daily distillate yield of 1.4 kg/m2 and 2.5 kg/m2, respectively. The ESM boosts water evaporation during the day and releases heat at night, resulting in a higher distillate yield than CSS. Meanwhile, the exergy efficiency (?exe) of CSS and SSWESM were 4.99% and 12.55% respectively. Also the SSWESM gives 72.6% more daily efficiency (?) than CSS.The authors extend their appreciation to the Deanship of Scientific Research at Imam Mohammad Ibn Saud Islamic University for funding this work through Research Group no. RG-21-12-03.Scopu