A numerical approach to assess the impact of the SLM laser parameters on thermal variables

Due to extraordinarily high heating and cooling rates, understanding the selective laser melting (SLM) process remains a challenge. To evaluate the impact of processing parameters on distinct underlying surfaces, a three-dimensional finite element model is presented. To forecast the temperature distribution inside a finite solid model, a moving Gaussian heat source was created to scan the model with temperature-dependent material properties. In the finite model, the impact of processing factors such as laser power, scan rate, and scan spacing were investigated to measure thermal variables such as cooling rate, thermal gradient, and solidification rate in a layer with solid and powder bases. The maximum track temperature was observed to be increasing over the whole track length, which had a substantial influence on the thermal gradient, cooling rate, and solidification rate. The maximum track temperature, melt pool form, and thermal variables were shown to be strongly influenced by laser power and scan speed when compared to scan spacing. Furthermore, the underlying base had a substantial influence on the observed temperature values and melt pool shap

Steering system design of the second generation Formula SAE

The aim of this paper is to design the steering system of the formula racing car. This includes the designing of its main components in solidworks, its analysis by calculation and finite element simulation. Load acting on the wheels of formula car are calculated and input in the analysis wherever necessary. The cars steering rack is repositioned to avoid any collision with a-arms. The force acting on the bolts at tie rod, clevis and mounting bracket is found below its yield strength. The clevis attached at the end of the rack is subject to load and fatigue analysis in ANSYS and all results were found satisfactory. Similar analysis is done for rack arm at critical areas and its was found that region where the rack arm can withstand fluctuations ranging for almost whole life till failure. Later the whole steering system was split into three major components (Steering column assembly, steering rack assembly, Tie rod assemblies) and each component is designed separately in SolidWorks and then assembled into whole one. SKF SAKAC 10 M ends are selected rod ends for steering arm assembly allowing rigid force transfer between rack arms and upright assembly as well as vertical motion of wheel assembly in operation. In the assembly 6 x M8 and 4 x M10 exist with the associated washers and nuts. The universal joint connecting the two steering column was machined according to Australian standards with splines at both ends. Two splined steering columns was machined in order to complete the steering column assembly. In order to stop the clevis colliding with the steering with the rack on full lock and to restrict the steering of the vehicle two locking collars were manufactured

Infuence of Post‑processing on Additively Manufactured Lattice Structures

The rapid evolution in additive manufacturing (AM) technology advocates a periodic assessment of the recent progress in the process and product developments. One such area is lattice structure (LS) fabrication with controlled porosity, especially microscale triply periodic minimal surfaces. These nature-inspired and mechanically robust complex cellular structures are making signifcant progress in aerospace, automotive, and biomedical applications. However, limitations in the AM process, such as process-induced defects, microstructural heterogeneities, and post-processing challenges, may result in an inaccurate assessment of mechanical properties. This review paper presents a comprehensive overview of challenges in the fabrication of AM cellular structures, LS classifcation, simulation outline, and the efect of post-processing on their overall mechanical and microstructural development. It further provides a physical assessment and the underlying science of failure criteria and deformation mechanism of AM lattice structures. This review includes substantive discussions on LS topology, relative density, AM defects, and material type, critically analyzing the printability of various engineering alloys based on experimental and numerical studies. Finally, the knowledge gaps in the scientifc understanding and the future research needs for the expansion of AM lattice materials are provided

Influence of post-processing on additively manufactured lattice structures

The rapid evolution in additive manufacturing (AM) technology advocates a periodic assessment of the recent progress in the process and product developments. One such area is lattice structure (LS) fabrication with controlled porosity, especially microscale triply periodic minimal surfaces. These nature-inspired and mechanically robust complex cellular structures are making significant progress in aerospace, automotive, and biomedical applications. However, limitations in the AM process, such as process-induced defects, microstructural heterogeneities, and post-processing challenges, may result in an inaccurate assessment of mechanical properties. This review paper presents a comprehensive overview of challenges in the fabrication of AM cellular structures, LS classification, simulation outline, and the effect of post-processing on their overall mechanical and microstructural development. It further provides a physical assessment and the underlying science of failure criteria and deformation mechanism of AM lattice structures. This review includes substantive discussions on LS topology, relative density, AM defects, and material type, critically analyzing the printability of various engineering alloys based on experimental and numerical studies. Finally, the knowledge gaps in the scientific understanding and the future research needs for the expansion of AM lattice materials are provided

Design, Modelling, Fabrication, and Testing of Vertical Milling Machine Fixture for Friction Stir Welding Operation

In this work, a simple and robust fixture was designed, modeled, and fabricated for facilitating the friction stir welding process on a vertical milling machine with easy loading/unloading of workpieces. Four different structural materials, i.e., Mild Steel (MS), Grey Cast Iron (GCI), Die Steel (DS), and Hard alloy (HA), were considered for the fixture material. CAD software designed model of the fixture was imported to finite element solver for stress-deformation analysis. From the results of dynamics analysis, Mild Steel showed better performance, i.e., maximum deformation 0.14719 mm and comparable equivalent stress 42.724 MPa as compared to GCI (0.28196 mm, 42.821 MPa), DS (0.15508 mm, 42.821 MPa), and HA (0.17231 mm, 42.821 MPa). Furthermore, MS is commercially available easily than the other three. Therefore, the Mild Steel block was used to fabricate the Friction Stir Welding fixture, and the testing of the fabricated fixture was then carried out by running the FSW experiments. Hardness measurements of the tested specimen proved the practical applicability of fabricated fixture. It was observed that developed fixture reduced set-up time significantly and facilitated a wide range of tool profile machining

Abstracts of National Conference on Research and Developments in Material Processing, Modelling and Characterization 2020

This book presents the abstracts of the papers presented to the Online National Conference on Research and Developments in Material Processing, Modelling and Characterization 2020 (RDMPMC-2020) held on 26th and 27th August 2020 organized by the Department of Metallurgical and Materials Science in Association with the Department of Production and Industrial Engineering, National Institute of Technology Jamshedpur, Jharkhand, India. Conference Title: National Conference on Research and Developments in Material Processing, Modelling and Characterization 2020Conference Acronym: RDMPMC-2020Conference Date: 26–27 August 2020Conference Location: Online (Virtual Mode)Conference Organizer: Department of Metallurgical and Materials Engineering, National Institute of Technology JamshedpurCo-organizer: Department of Production and Industrial Engineering, National Institute of Technology Jamshedpur, Jharkhand, IndiaConference Sponsor: TEQIP-