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Number of results: 11
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Abstract

The influence of the processing temperature of polylactide (PLA) on the structure geometry changing (SGC) and its functional properties were analyzed. The PLA samples subjected to testing were manufactured using incremental fused deposition modeling technology (FDM) with processing temperatures ranging from 180°C to 230°C. The topography of the PLA surfaces formed during heat dissipation and generated by the work table was analyzed. The roughness measurements were carried out using the profile method in accordance with PN ISO 3274: 2011. Registered profiles of the surfaces were analyzed numerically in fractal terms using the method of the S(Δx) structure function. The functional properties of the PLA surface were evaluated on the basis of Abbott-Firestone curves, according to PN EN ISO 13565–2: 1999.

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Authors and Affiliations

B. Pszczółkowski
M. Bramowicz
ORCID: ORCID
W. Rejmer
T. Chrostek
C. Senderowski
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Abstract

3D printing in FDM (Fused Deposition Modelling) technology is commonly used, mainly in the preparation of prototypes, but also for the production of ready-made elements. Objects printed using the FDM method have characteristic, adverse surface features related to the limitations of this technology. That is why surface treatment of 3D prints becomes crucial. One of the method is metal plating of elements. The most frequently used material in FDM technology is PLA (polylactic acid) and ABS (acrylonitrile butadiene styrene). Study of surface parameters determination for ABS prints after galvanic copper plating is presented in this paper. For this purpose, samples printed with ABS were smoothed in acetone vapour. Most favorable parameters of the surface were obtained for samples that had contact with acetone vapour for 60 minutes. Ultimately, surface analysis of samples after graphite coating and subjected to copper plating was performed. It was found that surface parameters are close to results obtained with traditional methods of metal processing.

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Authors and Affiliations

T. Maciąg
J. Wieczorek
W. Kałsa
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Abstract

This paper presents results of a research on the possibilities of applying 3D printed casting models for small production series as alternative to traditional tooling production on automated DisaMatch mould production lines. The main task was to verify and compare the dimensions of the 3D printed models before and after moulding process. The paper discusses main advantages and disadvantages of the 3D printing methods used like FDM (Fused Deposition Modeling)/FFF (Fused Filament Fabrication), SLA (stereolitography) and DPP (Daylight Polymer Printing). Measurement of casting model outside dimension change resulting from moulding sand friction on their surface was made with the use of GOM INSPECT software on the basis of 3D scans made with ATOS TripleScan optical scanner. Hardness of 3D printed models made of ABS, Z-ULTRAT, three different photopolymer resins (from FormLab and Liquid Crystal companies) was verified. The result of the research printed models usability for the foundry industry was presented.

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Authors and Affiliations

Ł. Bernat
A. Kroma
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Abstract

Additive manufacturing (AM) technologies have been gaining popularity in recent years due to patent releases – and in effect – better accessibility of the technology. One of the most popular AM technologies is fused deposition modeling (FDM), which is used to manufacture products out of thermoplastic polymers in a layer-by-layer manner. Due to the specificity of the method, parts manufactured in this manner tend to have non-isotropic properties. One of the factors influencing the part’s mechanical behavior and quality is the thermoplastic material’s bonding mechanism correlated with the processing temperature, as well as thermal shrinkage during processing. In this research, the authors verified the suitability of finite element method (FEM) analysis for determining PET-G thermal evolution during the process, by creating a layer transient heat transfer model, and comparing the obtained modelling results with ones registered during a real-time process recorded with a FLIR T1020 thermal imaging camera. Our model is a valuable resource for providing thermal conditions in existing numerical models that connect heat transfer, mesostructure and AM product strength, especially when experimental data is lacking. The FE model presented reached a maximum sample-specific error of 11.3%, while the arithmetic mean percentage error for all samples and layer heights is equal to 4.3%, which the authors consider satisfactory. Model-to-experiment error is partially caused by glass transition of the material, which can be observed on the experimental cooling rate curve after processing the temperature signal.
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Authors and Affiliations

Łukasz Kowalski
1
ORCID: ORCID
Michał Bembenek
1
ORCID: ORCID
Andrzej Uhryński
2
ORCID: ORCID
Szymon Bajda
3
ORCID: ORCID

  1. Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Krakow,Al. Adama Mickiewicza 30,230-059 Kraków, Poland
  2. Department of Machine Design and Maintenance, Faculty of Mechanical Engineering and Robotics, AGH University of3Krakow,Al. Adama Mickiewicza 30, 30-059 Kraków, Poland
  3. Faculty of Metals Engineering and Industrial Computer Science, AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059, Kraków, Poland
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Abstract

The purpose of this study is to determine the effect of manufacturing conditions on the mechanical properties and structure of ABS parts. Two sets of samples with the same geometric characteristics were produced by fused deposition modelling (FDM) and injection molding (IM). The molding pressure and cooling rate were found to have a significant effect on shaping the mechanical properties and structure of ABS products. The manufacturing method and adopted process parameters have a significant impact on the degree of packing of macromolecules in the volume of the product and thus determine its density. Selected mechanical properties were determined and compared with their specific gravity. The research was carried out using tools and machines, i.e. injection molds of unique design and standard measuring stations. Tensile and bending strengths and Young’s modulus were related to the density of products obtained under different process conditions and having gradient and solid structures. The results provide useful information for engineers designing products using FDM technology. Relating tensile and flexural strength and Young’s modulus to the specific gravity of the product. It was found that the value of product properties is closely related to various process conditions, which further provides a true description of the products.
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Authors and Affiliations

Piotr Czyżewski
1
Dawid Marciniak
1
ORCID: ORCID
Dariusz Sykutera
1
ORCID: ORCID

  1. Department of Manufacturing Techniques, Faculty of Mechanical Engineering, Bydgoszcz University of Science and Technology,Kaliskiego 7, 85-796 Bydgoszcz, Poland
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Abstract

Additive manufacturing in recent years has become one of the fastest growing technologies.

The increasing availability of 3D printing devices means that every year more and more

devices of this type are found in the homes of ordinary people. Unfortunately, air pollution is

formed during the process. Their main types include Ultra Fine Particles (UFP) and Volatile

Compounds (VOC). In the event of air flow restriction, these substances can accumulate in

the room and then enter the organisms of people staying there. The article presents the

main substances that have been identified in various studies available in literature. Health

aspects and potential threats related to inhalation of substances contained in dusts and gases

generated during the process are shown, taking into account the division into individual types

of printing materials. The article also presents the differences between the research results

for 3d printing from individual plastics among different authors and describes possible causes

of discrepancies.

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Authors and Affiliations

Anna Karwasz
Filip Osinski
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Abstract

The article presents results of research on the influence of the mould material on selected mechanical properties of wax models used for production of casting in investment casting method. The main goal was to compare the strength and hardness of samples produced in various media in order to analyse the applicability of the 3D printing technology as an alternative method of producing wax injection dies. To make the wax injection dies, it was decided to use a milled steel and 3D printed inserts made using FDM (Fused Deposition Modeling) / FFF (Fused Filament Fabrication) technology from HIPS (High Impact Polystyrene) and ABS (Acrylonitrile Butadiene Styrene). A semi-automatic vertical reciprocating injection moulding machine was used to produce the wax samples made of Freeman Flakes Wax Mixture – Super Pink. During injection moulding process, the mould temperature was measured each time before and after moulding with a pyrometer. Then, the samples were subjected to a static tensile test and a hardness test. It was shown that the mould material influences the strength properties of the wax samples, but not their final hardness.
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Bibliography

[1] Campbell, J. (2015). Complete casting handbook: metal casting processes, techniques and design. (2nd ed.). Oxford: Butterworth-Heinemann.
[2] Tamta, K. & Karunakar, D.B. (2020). Development of hybrid pattern material for investment casting process: an experimental investigation on improvement in pattern characteristics. Materials and Manufacturing Processes. 36(6), 744-751. DOI: 10.1080/10426914.2020.1854471.
[3] Bernat, L. & Popielarski, P. (2020). Identification of substitute thermophysical properties of gypsum mould. Archives of Foundry Engineering. 20(1), 5-8. DOI: 10.24425/afe.2020.131274.
[4] Guzera, J. (2010). Casting production in autoclaved gypsum moulds using investment casting method. Archives of Foundry Engineering. 10(3), 307-310. (in Polish).
[5] Sarbojeet, J. (2016). Crystallization behavior of waxes. Doctoral dissertation. Utah State University, Logan, United States of America.
[6] Unknown author, Investment casting process steps (lost wax). Retrieved January 12, 2021, from http://americancastingco.com/investment-casting-process.
[7] Ruwoldt, J., Humborstad Sørland, G., Simon, S., Oschmann, H-J. & Sjoblom, J. (2019). Inhibitor-wax interactions and PPD effect on wax crystallization: New approaches for GC/MS and NMR, and comparison with DSC, CPM, and rheometry. Journal of Petroleum Science and Engineering. 177. 53-68. DOI: 10.1016/j.petrol.2019.02.046
[8] Jung, T., Kim, J-N. & Kang, S-P. (2016). Influence of polymeric additives on paraffin waxes crystallization in model oils. Korean Journal of Chemical Engineering. 33(6), 1813-1822. DOI: https:://doi.org/10.1007/s11814-016-0052-3.
[9] Simnofske, D. & Mollenhauer, K. (2017). Effect of wax crystallization on complex modulus of modified bitumen after varied temperature conditioning rates. IOP Conference Series: Materials Science and Engineering. 236. DOI: 10.1088/1757-899X/236/1/012003.
[10] Edwards, R.T. (1957). Crystal Habit of Paraffin Wax. Industrial & Engineering Chemistry. 49(4), 750-757. DOI: https://doi.org/10.1021/ie50568a042.
[11] Dantas Neto A.A., Gomes, E.A.S. & Barros Neto, E.L., Dantas, T.N.C. & Moura C.P.A.M. (2009). Determination of wax appearance temperature (WAT) in paraffin/solvent systems by photoelectric signal and viscosimetry. Brazilian Journal of Petroleum and Gas. 3(4), 149-157. ISSN: 1982- 0593.
[12] Unknown author, Freeman super pink flake wax: technical data sheet. Retrieved January 12, 2021, from https://www.freemanwax.com/datasheets/Injection/tdssuperpink.pdf.
[13] Unknown author, M-series-specification. Retrieved January 12, 2021, from https://support.zortrax.com/m-seriesspecification/.
[14] Clarke, E.W. (1951). Crystal Types of Pure Hydrocarbons in the Paraffin Wax Range. Industrial & Engineering Chemistry. 43(11), 2526–2535. DOI: https://doi.org/10.1021/ie50503a037
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Authors and Affiliations

A. Kroma
1
P. Brzęk
1

  1. Poznan University of Technology, Institute of Materials Technology, Division of Foundry, Piotrowo 3, 61-138 Poznań, Poland
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Abstract

Buildings consume half of all energy use and are also responsible for a similar proportion of carbon dioxide emission. The heat transfer across the building envelope - the shell of a house that separates the inside and outside - should generally be minimized. In the paper validation and verification based on Building Energy Simulation Test (BESTEST) of Energy3D computer code is presented. Next, computations performed by means of Energy 3D and Energy Plus for BESTEST building are compared. In the last part of the paper results for computations for real building are presented. Program Energy 3D proved to be an excellent tool for qualitative and quantitative analysis of buildings with respect to energy consumption.

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Authors and Affiliations

R.R. Gajewski
T. Kułakowski
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Abstract

In sand casting, Fused Deposition Modeling (FDM) printing by using Poly Lactic Acid (PLA) filament is one of the innovative foundry technologies being adopted to substitute traditional pattern making. Several literatures have reported the influence of process parameters such as raster angle and print speed on some mechanical properties of FDM-printed, PLA-prototypes used in other applications. This study investigated the effects of interior fill, top solid layer, and layer height on the compressive strength of rapid patterns for sand casting application. Different values of the process parameters were used to print the pre-defined samples of the PLA-specimens and a compression test was performed on them. The coupled effects of the process parameters on compressive strength were investigated and the optimum values were determined. Interior fill of 36%, layer height of 0.21 mm and top solid layer of 4 were found to produce a FDM-printed, PLApattern that sustained a compaction pressure of 0.61 MPa. A simulation analysis with ANSYS® to compare failure modes of both experiment and model shows a similarity of buckling failure that occurred close to the base of each specimen.
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Authors and Affiliations

P.I. Anakhu
C.C. Bolu
A.A. Abioye
G. Onyiagha
H. Boyo
K. Jolayemi
J. Azeta
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Abstract

In longwall absolute methane emission rate forecasting, the range of the destressing zone is determined empirically and is not considered to be dependent on the geomechanical parameters of the rock strata. This simplification regarding destressing zone determination may result in significant differences between the forecast and the actual methane emission rates. During the extraction of coal seams using a system involving longwalls with caving under the conditions of low rock mass geomechanical parameters, the absolute methane emission rate forecasts are typically underestimated in comparison to the actual methane emission rates.

In order to examine the influence of the destressing zones on the final forecasting result and to assess the influence of the rock mass geomechanical parameters on the increased accuracy of forecast values, destressing zones were determined for three longwalls with lengths ranging from 186 to 250 m, based on numerical modelling using the finite difference method (FDM). The modelling results confirmed the assumptions concerning the upper destressing zone range adopted for absolute methane emission rate forecasting. As for the remaining parameters, the destressing zones yielded great differences, particularly for floor strata. To inspect the accuracy of the FDM calculation result, an absolute methane emission rate forecasting algorithm was supplemented with the obtained zones. The prepared forecasts, both for longwall methane emission rates as well as the inflow of methane to the longwalls from strata within the destressing zone, were verified via underground methane emission tests. A comparative analysis found that including geomechanical parameters in methane emission rate forecasting can significantly reduce the errors in forecast values.

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Authors and Affiliations

Andrzej Walentek
Krystian Wierzbiński
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Abstract

Fused Deposition Modeling (FDM) components are commonly used for either prototypes or end products, mostly made of polymers. Polymers offer low frictional resistance to wear, so most of the engineering polymers find their increased usage in day-to-day industrial as well as domestic needs. The influence of many process controlling elements on the mechanical part properties is already being studied extensively, which demands the study of tribological characteristics like friction and wear rate under varying normal load (NL), sliding velocities (V) and part building orientations (PBO). The results showed a significant impact of the PBO and NL at various V on the tribological properties under various significant suitable sliding circumstances. Cracks were formed in the cylindrical tribometer specimens of Acrylonitrile butadiene styrene (ABS) fabricated at low PBO when operated at high NL, and V. Vertical PBO to the FDM building platform in the layers form where a number of inter-layers can bear maximum NL at higher values of V resulted in uniform wear and low frictions. Friction was noticed very low at minimum NL when PBO was 0° (horizontal) and 90° (vertical), but increased at high NL between PBO of 15° to 60°. The FDM parts improved compared to those from conventional manufacturing processes.
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Bibliography

[1] D. Ahn, J.-H. Kweon, S. Kwon, J. Song, and S. Lee. Representation of surface roughness in fused deposition modeling. Journal of Materials Processing Technology, 209(15-16):5593–5600, 2009. doi: 10.1016/j.jmatprotec.2009.05.016.
[2] C.K. Chua, S.H. Teh, and R.K.L. Gay. Rapid prototyping versus virtual prototyping in product design and manufacturing. The International Journal of Advanced Manufacturing Technology, 15(8):597–603, 1999. doi: 10.1007/s001700050107.
[3] W. Zeng, F. Lin, T. Shi, R. Zhang, Y. Nian, J. Ruan, and T Zhou. Fused deposition modelling of an auricle framework for microtia reconstruction based on CT images. Rapid Prototyping Journal, 15(5):280–284, 2008. doi: 10.1108/13552540810907947.
[4] S.H. Choi and H.H. Cheung. Multi-material virtual prototyping for product development and biomedical engineering. Computers in Industry, 58(5):438–452, 2007. doi: 10.1016/j.compind.2006.09.002.
[5] E.C. Santos, M. Shiomi, K. Osakada, and T. Laoui. Rapid manufacturing of metal components by laser forming. International Journal of Machine Tools and Manufacture, 46(12-13):1459–1468, 2006. doi: 10.1016/j.ijmachtools.2005.09.005.
[6] N. Oxman. Variable property rapid prototyping. Virtual and Physical Prototyping, 6(1):3–31, 2011. doi: 10.1080/17452759.2011.558588.
[7] A. Bellini, L. Shor, and S.I. Guceri. New developments in fused deposition modeling of ceramics. Rapid Prototyping Journal, 11(4):214–220, 2005. doi: 10.1108/13552540510612901.
[8] K.D. Dearn, T.J. Hoskins, D.G. Petrov, S.C. Reynolds, and R. Banks. Applications of dry film lubricants for polymer gears. Wear, 298-299:99–108, 2013. doi: 10.1016/j.wear.2012.11.003.
[9] S.E. Franklin. Wear experiments with selected engineering polymers and polymer composites under dry reciprocating sliding conditions. Wear, 251(1-12):1591–1598, 2001. doi: 10.1016/S0043-1648(01)00795-5.
[10] P.V. Vasconcelos, F.J. Lino, A.M. Baptista, and R.J. Neto. Tribological behaviour of epoxy based composites for rapid tooling. Wear, 260(1-2):30–39, 2006. doi: 10.1016/j.wear.2004.12.030.
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[12] A. Equbal, A.K. Sood, V. Toppo, R.K. Ohdar, and S.S. Mahapatra. Prediction and analysis of sliding wear performance of fused deposition modelling-processed ABS plastic parts. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 224(12):1261–1271, 2010. doi: 10.1243/13506501JET835.
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[19] M.M. Hanon, Y. Alshammas, and L. Zsidai. Effect of print orientation and bronze existence on tribological and mechanical properties of 3D-printed bronze/PLA composite. The International Journal of Advanced Manufacturing Technology, 108:553–570, 2020. doi: 10.1007/s00170-020-05391-x.
[20] M.N.M. Norani M.I.H.C. Abdullah, M.F.B. Abdollah, H. Amiruddin, F.R. Ramli, and N. Tamaldin. Tribological analysis of a 3D-printed internal triangular flip ABS pin during running-in stage. Jurnal Tribologi, 27:42–56, 2020.
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Authors and Affiliations

Turki Alamro
1
ORCID: ORCID
Mohammed Yunus
1
ORCID: ORCID
Rami Alfattani
1
ORCID: ORCID
Ibrahim A. Alnaser
2

  1. Department of Mechanical Engineering, Umm Al-Qura University, Makkah City, Saudi Arabia.
  2. Mechanical Engineering Department, King Saud University, Riyadh, Saudi Arabia.

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