5 research outputs found
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A Genetic Algorithm with Design of Experiments Approach to Predict the Optimal Process Parameters for FDM
This paper describes a Genetic Algorithm (GA) with Design of Experiments (DoE)
approach to predict the optimized surface roughness and porosity characteristics of the parts
produced using ABS material on stratasys FDM 2000 machine. The Mathematical Model (MM)
was developed by using Response Surface Methodology (RSM). It is to predict and investigate
the influence of selected process parameters namely slice thickness, road width, liquefier
temperature and air gap and their interactions on the surface roughness and porosity. The
developed MM is the fitness function in GA in order to find out the optimal sets of process
parameters and to predict the corresponding surface quality characteristics. These results have
been validated and the experimental results after GA are found to be in conformance with the
predicted process parameters.Mechanical Engineerin
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Design and Freeform Fabrication of Deployable Structures with Lattice Skins
Frontier environments—such as battlefields, hostile territories, remote locations, or outer
space—drive the need for lightweight, deployable structures that can be stored in a compact
configuration and deployed quickly and easily in the field. We introduce the concept of lattice
skins to enable the design, solid freeform fabrication (SFF), and deployment of customizable
structures with nearly arbitrary surface profile and lightweight multi-functionality. Using
Duraform FLEX® material in a selective laser sintering machine, large deployable structures are
fabricated in a nominal build chamber by either virtually collapsing them into a condensed form
or decomposing them into smaller parts. Before fabrication, lattice sub-skins are added
strategically beneath the surface of the part. The lattices provide elastic energy for folding and
deploying the structure or constrain expansion upon application of internal air pressure. Nearly
arbitrary surface profiles are achievable and internal space is preserved for subsequent usage. In
this paper, we present the results of a set of experimental and computational models that are
designed to provide proof of concept for lattice skins as a deployment mechanism in SFF and to
demonstrate the effect of lattice structure on deployed shape.Mechanical Engineerin
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Topology Design and Freeform Fabrication of Deployable Structures with Lattice Skins
Solid freeform fabrication is particularly suitable for fabricating customized parts, but it has not
been used for fabricating deployable structures that can be stored in a compact configuration and
deployed quickly and easily in the field. In previous work, lattice structures have been
established as a feasible means of deploying parts. Before fabricating the parts with a selective
laser sintering (SLS) machine and Duraform® Flex material, lattice sub-skins are added
strategically beneath the surface of the part. The lattice structure provides elastic energy for
folding and deploying the structure or constrains expansion upon application of internal air
pressure. In this paper, a procedure is presented for optimizing the lattice skin topology for
improved overall performance of the structure, measured in terms of deviation from desired
surface profile. A ground structure-based topology optimization procedure is utilized, with a
penalization scheme that encourages convergence to sets of thick lattice elements that are
manufacturable and extremely thin lattice elements that are removed from the final structure. A
deployable wing is designed for a miniature unmanned aerial vehicle. A physical prototype of
the optimal configuration is fabricated with SLS and compared with the virtual prototype.Mechanical Engineerin