Search results for: hybrid manufacturing

Authors: Wael I. Alnahhal

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It is a major challenge to build a bridge superstructure that has long-term durability and low maintenance requirements. A solution to this challenge may be to use new materials or to implement new structural systems. Fiber reinforced polymer (FRP) composites have continued to play an important role in solving some of persistent problems in infrastructure applications because of its high specific strength, light weight, and durability. In this study, the concept of the hybrid FRP-concrete structural systems is applied to a bridge superstructure. The hybrid FRP-concrete bridge superstructure is intended to have durable, structurally sound, and cost effective hybrid system that will take full advantage of the inherent properties of both FRP materials and concrete. In this study, two hybrid FRP-concrete bridge systems were investigated. The first system consists of trapezoidal cell units forming a bridge superstructure. The second one is formed by arch cells. The two systems rely on using cellular components to form the core of the bridge superstructure, and an outer shell to warp around those cells to form the integral unit of the bridge. Both systems were investigated analytically by using finite element (FE) analysis. From the rigorous FE studies, it was concluded that first system is more efficient than the second.

Keywords: bridge superstructure, hybrid system, fiber reinforced polymer, finite element analysis

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Authors: Safa Boudhaouia, Mohamed Amen Gahbiche, Eliane Giraud, Wacef Ben Salem, Philippe Dal Santo

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Multi-point forming (MPF) and asymmetric incremental forming (ISF) are two flexible processes for sheet metal manufacturing. To take advantages of these two techniques, a hybrid process has been developed: The Multipoint Incremental Forming (MPIF). This process accumulates at once the advantages of each of these last mentioned forming techniques, which makes it a very interesting and particularly an efficient process for single, small, and medium series production. In this paper, an experimental and a numerical investigation of this technique are presented. To highlight the flexibility of this process and its capacity to manufacture standard and complex shapes, several pieces were produced by using MPIF. The forming experiments are performed on a 3-axis CNC machine. Moreover, a numerical model of the MPIF process has been implemented in ABAQUS and the analysis showed a good agreement with experimental results in terms of deformed shape. Furthermore, the use of an elastomeric interpolator allows avoiding classical local defaults like dimples, which are generally caused by the asymmetric contact and also improves the distribution of residual strain. Future works will apply this approach to other alloys used in aeronautic or automotive applications.

Keywords: incremental forming, numerical simulation, MPIF, multipoint forming

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Authors: Elyes Zarrouk, Yassine Benayed, Faiez Gargouri

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This paper presents a new hybrid model for isolated Arabic words recognition. To do this, we apply Support Vectors Machine (SVM) as an estimator of posterior probabilities within the Dynamic Bayesian networks (DBN). This paper deals a comparative study between DBN and SVM/DBN systems for multi-dialect isolated Arabic words. Performance using SVM/DBN is found to exceed that of DBNs trained on an identical task, giving higher recognition accuracy for four different Arabic dialects. In fact, the average of recognition rates for the four dialects with SVM/DBN was 87.67% while 83.01% with DBN.

Keywords: dynamic Bayesian networks, hybrid models, supports vectors machine, Arabic isolated words

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Authors: Saumyaranjan Sahoo, Sudhir Yadav

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Indian manufacturing firms operating in rapidly changing and highly competitive market, over the last few decades, have embraced organization-wide transformation to achieve cultural and operational excellence. In recent years, numerous approaches have been proposed to improve business and manufacturing performance. Lean practices in particular, Total Productive Management (TPM) and Total Quality Management (TQM) have received considerable attention, as they being adopted and adapted for raising the performance standard of Indian manufacturing firms to world class levels. The complementary nature of TPM and TQM is being practiced in many companies to achieve synergy. Specifically, this research investigates whether joint TPM-TQM implementation contribute to higher business performance when compared to individual implementation. Data from 160 manufacturing firms were analyzed that demonstrate synergetic implementation of both TPM-TQM practices over a reasonable period of time, contributed in delivering better business performance as compared to individual implementation strategy.

Keywords: total productive management, total quality management, Indian manufacturing firms, business performance

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Authors: Arash Rahmani, Ahmad Ghanbari, Abbas Baghernezhad, Babak Safaei

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In the design of parallel manipulators, usually mean value of a dexterity measure over the workspace volume is considered as the objective function to be used in optimization algorithms. The mentioned indexes in a hybrid parallel manipulator (HPM) are quite complicated to solve thanks to infinite solutions for every point within the workspace of the redundant manipulators. In this paper, spatial isotropic design axioms are extended as a well-known method for optimum design of manipulators. An upper limit for the isotropy measure of HPM is calculated and instead of computing and minimizing isotropy measure, minimizing the obtained limit is considered. To this end, two different objective functions are suggested which are obtained from objective functions of comprising modules. Finally, by using genetic algorithm (GA), the best geometric parameters for a specific hybrid parallel robot which is composed of two modified Gough-Stewart platforms (MGSP) are achieved.

Keywords: hybrid manipulator, spatial isotropy, genetic algorithm, optimum design

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Authors: Krzysztof Rafał, Weronika Radziszewska, Hubert Biedka, Oskar Grabowski, Krzysztof Mik

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We present a method to choose energy storage technologies and their parameters for the economic operation of a microgrid. A grid-connected system with local loads and PV generation is assumed, where an energy storage system (ESS) is attached to minimize energy cost by providing energy balancing and arbitrage functionalities. The ESS operates in a hybrid configuration and consists of two unique technologies operated in a coordinated way. Based on given energy profiles and economical data a model calculates financial flow for ESS investment, including energy cost and ESS depreciation resulting from degradation. The optimization strategy proposes a hybrid set of two technologies with their respective power and energy ratings to minimize overall system cost in a given timeframe. Results are validated through microgrid simulations using real-life input profiles.

Keywords: energy storage, hybrid energy storage, cost-benefit analysis, microgrid, battery sizing

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Authors: Kun Zhou

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Additive manufacturing has emerged as a disruptive technology that is capable of manufacturing products with complex geometries through an accumulation of material feedstock in a layer-by-layer fashion. Laser additive manufacturing such as selective laser sintering has excellent printing resolution, high printing speed and robust part strength, and has led to a widespread adoption in the aerospace, automotive and biomedical industries. This talk highlights and discusses the recent work we have undertaken in the development of carbon nanotube-reinforced polyamide 12 (CNT/PA12) composites printed using laser additive manufacturing. Numerical modelling studies have been conducted to simulate various processes within laser additive manufacturing of CNT/PA12 composites, and extensive experimental work has been carried out to investigate the mechanical and functional properties of the printed parts. The results from these studies grant a deeper understanding of the intricate mechanisms occurring within each process and enables an accurate optimization of process parameters for the CNT/PA12 and other polymer composites.

Keywords: CNT/PA12 composites, laser additive manufacturing, process parameter optimization, numerical modeling

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Authors: Aslı Günay Bulutsuz, Mehmet Emin Yurci

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Severe plastic deformation techniques are top-down deformation methods which enable superior mechanical properties by decreasing grain size. Different kind severe plastic deformation methods have been widely being used at various process temperature and geometries. Besides manufacturing advantages of severe plastic deformation technique, most of the types are being used only at the laboratory level. They cannot be adapted to industrial usage due to their continuous manufacturability and manufacturing costs. In order to enhance these manufacturing difficulties and enable widespread usage, different kinds of methods have been developed. In this review, a comprehensive literature research was fulfilled in order to highlight continuous severe plastic deformation methods.

Keywords: continuous manufacturing, severe plastic deformation, ultrafine grains, grain size refinement

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Authors: Umesh Kumar Soni, Suresh Kumar Soni, S. R. Awasthi

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Worldwide biggest difficulties are climate change, future availability of fossil fuels, and economical feasibility of renewable energy. They force us to use to a greater extent renewable energy and develop suitable hybrid renewable systems. Building heating/cooling consumes significant amount of energy. It can be conserved by use of proper heating/cooling techniques. This paper reviews and critically analyzes various active, passive and hybrid heating/cooling techniques used in green buildings.

Keywords: natural ventilation, energy conservation, hybrid ventilation techniques, climate change

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Authors: Gopinath Rathod, Vinod Puranik

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Sustainability is regarded as a key concept for survival in the competitive scenario. Industrial risk and diversification of risk type’s increases with industrial developments. In the context of sustainable manufacturing, the evaluation of risk is difficult because of the incomplete information and multiple indicators. Fuzzy Multiple Attribute Decision Method (FMADM) has been used with a three level hierarchical decision making model to evaluate aggregate risk for sustainable manufacturing projects. A case study has been presented to reflect the risk characteristics in sustainable manufacturing projects.

Keywords: sustainable manufacturing, decision making, aggregate risk, fuzzy logic, fuzzy multiple attribute decision method

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Authors: Shah Muhammad Butt, Ahmed Masaud Ansair

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Present financial crisis in Higher Educational Institutes (HEIs) is causing lots of problems such as considerable budget cuts, which makes it difficult to meet the ever growing IT based research and learning needs. Institutions are rapidly planning and promoting cloud based approaches for their academic and research needs. A cost-effective hybrid cloud framework for HEIs will provide educational services for campus or intercampus communication. Hybrid cloud framework comprises private and public cloud approaches. This paper will propose the framework based on the Open Source Cloud (OpenNebula for Virtualization, Eucalyptus for Infrastructure and Aneka for programming development environment) combined with CSPs services which are delivered to the end-user via the internet from public clouds such as Google, Microsoft, Zoho, and Salesforce.

Keywords: educational services, hybrid campus cloud, open source, higher educational institutes

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Authors: Safa Adi

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This paper will consider the problem of sequential mining patterns embedded in a database by handling the time constraints as defined in the GSP algorithm (level wise algorithms). We will compare two previous approaches GTC and PSP, that resumes the general principles of GSP. Furthermore this paper will discuss PG-hybrid algorithm, that using PSP and GTC. The results show that PSP and GTC are more efficient than GSP. On the other hand, the GTC algorithm performs better than PSP. The PG-hybrid algorithm use PSP algorithm for the two first passes on the database, and GTC approach for the following scans. Experiments show that the hybrid approach is very efficient for short, frequent sequences.

Keywords: database, GTC algorithm, PSP algorithm, sequential patterns, time constraints

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Authors: A. V. Ayanwale, S. M. Tsadu, S. L. Lamai, R. J. Kolo, Y. I. Auta, A. Z. Mohammed

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A twelve weeks experiment was carried out on Heteroclarias freshwater hybrid fish fingerlings under laboratory conditions to study the effects of different temperature levels, 26.91 (control), 28.00, 30.00, 32.00°C respectively and their physiological responses to oxygen consumption, ammonia excretion and opercular respiratory beats were evaluated. The oxygen consumption, ammonia excretion and opercular respiratory beats were determined weekly based on standard procedures. The findings revealed that the oxygen consumption of Heteroclarias hybrid fingerlings significantly (p<0.05) increased with increase in temperature. The ammonia excretion were not significantly different (p>0.05) in all the temperature levels. The opercular respiratory beats per minutes showed similar trend in weeks 1,2,4 and 8 but indicated significantly higher (p<0.05) opercular respiratory beats (range= 117.10±2.26 at 30oC to 142.75±3.04 opercular beat at 32oC in week 8) at highest tested temperature levels. However, there was a decreasing trend in the opercular respiratory beats per minute of the controlled fingerlings. Generally, the opercular respiratory beats per minute decreased with increase in fish size. The findings of this study confirmed that increase in water temperature affects the physiology of Heteroclarias hybrid and hence for effective rearing and for profit making, it is essential for the hybrid to be cultured in the temperature range between 26.91°C (control) and 28.00°C.

Keywords: heteroclarias, hybrid, physiological responses, temperature

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Authors: D. Garg, S. Luthra, A. Haleem

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Due to growing concern about environmental and social consequences throughout the world, a need has been felt to incorporate sustainability concepts in conventional manufacturing. This paper is an attempt to identify and evaluate drivers in implementing sustainable manufacturing in Indian context. Nine possible drivers for successful implementation of sustainable manufacturing have been identified from extensive review. Further, Decision Making Trial and Evaluation Laboratory (DEMATEL) approach has been utilized to evaluate and categorize these identified drivers for implementing sustainable manufacturing in to the cause and effect groups. Five drivers (Societal Pressure and Public Concerns; Regulations and Government Policies; Top Management Involvement, Commitment and Support; Effective Strategies and Activities towards Socially Responsible Manufacturing and Market Trends) have been categorized into the cause group and four drivers (Holistic View in Manufacturing Systems; Supplier Participation; Building Sustainable culture in Organization; and Corporate Image and Benefits) have been categorized into the effect group. “Societal Pressure and Public Concerns” has been found the most critical driver and “Corporate Image and Benefits” as least critical or the most easily influenced driver to implementing sustainable manufacturing in Indian context. This paper may surely help practitioners in better understanding of these drivers and their priorities towards effective implementation of sustainable manufacturing.

Keywords: drivers, decision making trial and evaluation laboratory (DEMATEL), India, sustainable manufacturing

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Authors: Masoud Taghavi, Gholamreza Salehi, Ali Lohrasbi Nichkoohi

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Despite the growing use of renewable energies in different fields of application of this technology in the field of water supply has been less attention. Photovoltaic and wind hybrid system is that new topics in renewable energy, including photovoltaic arrays, wind turbines, a set of batteries as a storage system and a diesel generator as a backup system is. In this investigation, first climate data including average wind speed and solar radiation at any time during the year, data collection and analysis are performed in the energy. The wind turbines in four models, photovoltaic panels at the 6 position of relative power, batteries and diesel generator capacity in seven states in the two models are combined hours of operation with renewables, diesel generator and battery bank check and a hybrid system of solar power generation-wind, which is optimized conditions, are presented.

Keywords: renewable energy, wind and solar energy, hybrid systems, cloning station

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Authors: Pawthawala Nancy Manish, Syed Alay Hashim

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A hybrid rocket is a rocket engine which uses propellants in two different states of matter- one is in solid and the other either gas or liquid. A hybrid rocket exhibit advantages over both liquid rockets and solid rockets especially in terms of simplicity, stop-start-restart capabilities, safety and cost. This paper deals the design and development of a hybrid rocket having paraffin wax as solid fuel and liquid oxygen as oxidizer. Due to variation of pressure in combustion chamber there is significantly change in mass flow rate, burning rate and uneven regression along the length of the grain. This project describes the working model of a hybrid propellant rocket motor. We have designed a hybrid rocket thrust chamber based on the predetermined combustion chamber pressure and the properties of hybrid propellant. This project is all ready in working condition with normal oxygen injector. Now we have planned to modify the injector design to improve the combustion property. We will use spray type injector for injecting the oxidizer. This idea will increase the performance followed by the regression rate of the solid fuel. By employing mass conservation law, oxygen mass flux, oxidizer/fuel ratio and regression rate the thrust coefficient can be obtained for our current design. CATIA V5 R20 is our design software for the complete setup. This project is fully based on experimental evaluation and the collection of combustion and flow parameters. The thrust chamber is made of stainless steel and the duration of test is around 15-20 seconds (Maximum). These experiments indicates that paraffin based fuel provides the opportunity to satisfy a broad range of mission requirements for the next generation of the hybrid rocket system.

Keywords: burning rate, liquid oxygen, mass flow rate, paraffin wax and sugar

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Authors: Daniel Nelson, Valeria La Saponara

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Material extrusion is an additive manufacturing modality that continues to show great promise in the ability to create low-cost, highly intricate, and exceedingly useful structural elements. As more capable and versatile filament materials are devised, and the resolution of manufacturing systems continues to increase, the need to understand and predict manufacturing-induced warping will gain ever greater importance. The following study presents an in situ remote sensing and data analysis construct that allows for the in situ mapping and quantification of surface displacements induced by residual stresses on a specified test structure. This proof-of-concept experimental process shows that it is possible to provide designers and manufacturers with insight into the manufacturing parameters that lead to the manifestation of these deformations and a greater understanding of the behavior of these warping events over the course of the manufacturing process.

Keywords: additive manufacturing, deformation, digital image correlation, fused filament fabrication, residual stress, warping

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Authors: Somayeh Komeylian

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The antenna arrays for the entire 3D spherical coverage have been developed for their potential use in variety of applications such as radars and body-worn devices of the body area networks. In this study, we have rigorously revamped the hybrid antenna array using the optimum geometry of bowtie elements for achieving a significant improvement in the angular discrimination capability as well as in separating two adjacent targets. In this scenario, we have analogously investigated the effectiveness of increasing the virtual array length in fostering and enhancing the directivity and angular resolution in the 10 GHz frequency. The simulation results have extensively verified that the proposed antenna array represents a drastic enhancement in terms of size, directivity, side lobe level (SLL) and, especially resolution compared with the other available geometries. We have also verified that the maximum directivities of the proposed hybrid antenna array represent the robustness to the all  variations, which is accompanied by the uniform 3D scanning characteristic.

Keywords: bowtie antenna, hybrid antenna array, array signal processing, body area networks

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Authors: Z. Abdollahnejad, P. Torgal, J. Barroso Aguiar

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Publications on the field of alkali-activated binders, state that this new material is likely to have high potential to become an alternative to Portland cement. Classical alkali-activated cements could be made more eco-efficient if the use of sodium silicate is avoided. Besides, most alkali-activated cements suffer from severe efflorescence originated by the fact that alkaline and/or soluble silicates that are added during processing cannot be totally consumed. This paper presents experimental results on hybrid alkaline cements. Compressive strength results and efflorescence’s observations show that the new mixes already analyzed are promising. SEM results show that no traditional porous ITZ was detected in these binders.

Keywords: hybrid alkaline cements, compressive strength, efflorescence, SEM, ITZ

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Authors: Divya Pande

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The dynamics of culture expresses itself in language. Even after India got independence in 1947 English subtly crept in the language of the masses with a silent and powerful flow towards the vernacular. The culture contact resulted in learning and emergence of a new language across the Hindi speaking belt of Northern and Central India. The hybrid words thus formed displaced the original word and got contextualized and absorbed in the language of the common masses. The research paper explores the interesting new vocabulary used extensively in the urban and rural districts of the state of Uttar- Pradesh which is the most populous state of India. The paper adopts a two way classification- formal and contextual for the analysis of the hybrid vocabulary of the linguistic items where one element is necessarily from the English language and the other from the Hindi. The new vocabulary represents languages of the wider world cutting across the geographical and the cultural barriers. The paper also broadly points out to the Hinglish commonly used in the state.

Keywords: assimilation, culture contact, Hinglish, hybrid words

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Authors: Abdullah M. Almeshal, Mohammad R. Alenezi, Muhammad Moaz

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In this paper, we discuss the performance of applying hybrid spiral dynamic bacterial chemotaxis (HSDBC) optimisation algorithm on an intelligent controller for a differential drive robot. A unicycle class of differential drive robot is utilised to serve as a basis application to evaluate the performance of the HSDBC algorithm. A hybrid fuzzy logic controller is developed and implemented for the unicycle robot to follow a predefined trajectory. Trajectories of various frictional profiles and levels were simulated to evaluate the performance of the robot at different operating conditions. Controller gains and scaling factors were optimised using HSDBC and the performance is evaluated in comparison to previously adopted optimisation algorithms. The HSDBC has proven its feasibility in achieving a faster convergence toward the optimal gains and resulted in a superior performance.

Keywords: differential drive robot, hybrid fuzzy controller, optimization, path tracking, unicycle robot

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Authors: Sandrine Delpeux-Ouldriane, Min Cai, Laurent Duclaux, Laurence Reinert, Fabrice Muller

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A novel hybrid adsorbent, based on chitosan biopolymer, clays and activated carbon was prepared. Hybrid chitosan beads containing dispersed clays and activated carbons were prepared by precipitation in basic medium. Such a composite material is still very porous and presents a wide adsorption spectrum. The obtained composite adsorbent is able to handle all the pollution types including heavy metals, polar and hydrophobic organic molecules and nitrates. It could find a place of choice in tertiary water treatment processes or for an ‘at source’ treatment concerning chemical or pharmaceutical industries.

Keywords: adsorption, chitosan, clay mineral, activated carbon

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Authors: Mohamed Haneef, Shanawaz Patil, Syed Zameer, Mohammed Mohsin Ali

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The emerging technologies and trends of present generation requires downsizing the unwieldy structures to light weight structures on one hand and integration of varied properties on other hand to meet the application demands. In the present investigation an attempt is made to familiarize and best possibilities of reinforcing agent in aluminum 7075 matrix with naturally occurring beryl (Be) and graphene (Gr) to develop a new hybrid composite material. A stir casting process was used to fabricate with fixed volume fraction of 6wt% weight beryl and various volume fractions of 0.5wt%, 1wt%, 1.5wt% and 2wt% of graphene. The properties such as tensile strength, hardness and dry sliding wear behavior of hybrid composites were examined. The crystallite size and morphology of the graphene and beryl particles were analyzed with X-ray diffraction (XRD) and scanning electron microscopy (SEM) respectively. It was observed that ultimate tensile strength and hardness of the hybrid composite increased with increasing reinforcement volume fraction as compared to specimen without reinforcement additions. The dry sliding wear behavior of the hybrid composites decreases as compared to Al7075 alloy without reinforcement.

Keywords: Al7075, beryl, graphene, TEM, wear

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Authors: Ahmad Rouhani, Masood Jabbari, Sima Honarmand

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This paper introduces a method to optimal design of a hybrid Wind/Photovoltaic/Fuel cell generation system for a typical domestic load that is not located near the electricity grid. In this configuration the combination of a battery, an electrolyser, and a hydrogen storage tank are used as the energy storage system. The aim of this design is minimization of overall cost of generation scheme over 20 years of operation. The Matlab/Simulink is applied for choosing the appropriate structure and the optimization of system sizing. A teaching learning based optimization is used to optimize the cost function. An overall power management strategy is designed for the proposed system to manage power flows among the different energy sources and the storage unit in the system. The results have been analyzed in terms of technics and economics. The simulation results indicate that the proposed hybrid system would be a feasible solution for stand-alone applications at remote locations.

Keywords: hybrid energy system, optimum sizing, power management, TLBO

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Authors: Chalakorn Chitsaart, Suchada Rianmora, Noppawat Vongpiyasatit

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In order to reduce the transportation time and cost for direct interface between customer and manufacturer, the image processing technique has been introduced in this research where designing part and defining manufacturing process can be performed quickly. A3D virtual model is directly generated from a series of multi-view images of an object, and it can be modified, analyzed, and improved the structure, or function for the further implementations, such as computer-aided manufacturing (CAM). To estimate and quote the production cost, the user-friendly platform has been developed in this research where the appropriate manufacturing parameters and process detections have been identified and planned by CAM simulation.

Keywords: image processing technique, feature detections, surface registrations, capturing multi-view images, Production costs and Manufacturing processes

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Authors: Mark Schudeleit, Christian Sieg, Ferit Küçükay

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This publication focuses on the limits and potentials of 48V hybrid systems, which are especially due to the cost advantages an attractive alternative, compared to established high volt-age HEVs and thus will gain relevant market shares in the future. Firstly, at market overview is given which shows the current known 48V hybrid concepts and demonstrators. These topologies will be analyzed and evaluated regarding the system power and the battery capacity as well as their implemented hybrid functions. The potential in fuel savings and CO2 reduction is calculated followed by the customer-relevant dimensioning of the electric motor and the battery. For both measured data of the real customer operation is used. Subsequently, the CO2 saving potentials of the customer-oriented dimensioned powertrain will be presented for the NEDC and the customer operation. With a comparison of the newly defined drivetrain with existing 48V systems the question can be answered whether current systems are dimensioned optimally for the customer operation or just for legislated driving cycles.

Keywords: 48V hybrid systems, market comparison, requirements and potentials in customer operation, customer-oriented dimensioning, CO2 savings

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Authors: Talha Ali Khan

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This paper presents an adaptive neuro-fuzzy interference system (ANFIS), which is applied to a hybrid stepper motor (HSM) to regulate its speed. The dynamic response of the HSM with the ANFIS controller is studied during the starting process and under different load disturbance. The effectiveness of the proposed controller is compared with that of the conventional PI controller. The proposed method solves the problem of nonlinearities and load changes of the HSM drives. The proposed controller ensures fast and precise dynamic response with an excellent steady state performance. Matlab/Simulink program is used for this dynamic simulation study.

Keywords: stepper motor, hybrid, ANFIS, speed control

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Authors: Ashish Lochan, Anil K. Dahiya, Amit Verma

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The idea of combining photovoltaic and solar thermal collector to provide electrical and heat energy is not new, however, it is an area of limited attention. Hybrid photovoltaic-thermals have become a focus point of interest in the field of solar energy. Integration of both (photovoltaic and thermal collector) provide greater opportunity for the use of renewable solar energy. This system converts solar energy into electricity and heat energy simultaneously. Theoretical performance analyses of hybrid PV/Ts have been carried out. Also, the temperature of water (as a heat carrier) have been calculated for different seasons with the help of TRANSYS.

Keywords: photovoltaic-thermal, solar energy, seasonal performance analysis, TRANSYS

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Authors: Anjian Chen, Joseph C. Chen

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This paper studies a case where the targeted surface roughness of fused deposition modeling (FDM) additive manufacturing process is improved. The process is designing to reduce or eliminate the defects and improve the process capability index Cp and Cpk for an FDM additive manufacturing process. The baseline Cp is 0.274 and Cpk is 0.654. This research utilizes the Taguchi methodology, to eliminate defects and improve the process. The Taguchi method is used to optimize the additive manufacturing process and printing parameters that affect the targeted surface roughness of FDM additive manufacturing. The Taguchi L9 orthogonal array is used to organize the parameters' (four controllable parameters and one non-controllable parameter) effectiveness on the FDM additive manufacturing process. The four controllable parameters are nozzle temperature [°C], layer thickness [mm], nozzle speed [mm/s], and extruder speed [%]. The non-controllable parameter is the environmental temperature [°C]. After the optimization of the parameters, a confirmation print was printed to prove that the results can reduce the amount of defects and improve the process capability index Cp from 0.274 to 1.605 and the Cpk from 0.654 to 1.233 for the FDM additive manufacturing process. The final results confirmed that the Taguchi methodology is sufficient to improve the surface roughness of FDM additive manufacturing process.

Keywords: additive manufacturing, fused deposition modeling, surface roughness, six-sigma, Taguchi method, 3D printing

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Authors: Asli Beyler Çi̇ği̇l, Memet Vezi̇r Kahraman

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Organic–inorganic hybrids have become an effective source of advanced materials because they combine the advantages of both the organic moiety such as flexibility, low dielectric constant, and processability, and inorganic moiety as rigidity, strength, durability, and thermal stability. By incorporating cross-linkable side chains, the hybrid materials can be made photosensitive and UV curable, which offers many advantages including low processing temperature, low equipment cost and compatibility. In this study, uv-curable organic-inorganic hybrid material, which was contained surface modified polyaniline particles (PANI), was prepared. PANI surface photografted with hydroxy ethyl methacrylate (HEMA) to produce hydroxyl groups. Hydroxyl functionalized PANI/HEMA was acrylated using isocyanato ethyl methacrylate (IEM) in order to improve the dispersion and interfacial interaction in composites. UV-curable formulation was prepared by mixing the surface modified PANI, polyethylene glycol diacrylate (PEGDA), trimethylolpropane triacrylate (TMPTA), hydrolized 3- methacryloxypropyltrimethoxysilane (hyd. MEMO) and photoinitiator. Chemical structure of nano-hybrid material was characterized by FTIR. FTIR spectra showed that the photografting of PANI was prepared successfully. Thermal properties of the nano-hybrid material were determined by thermogravimetric analysis (TGA). The morphology of the nano-hybrid material was performed by scanning electron microscopy (SEM).

Keywords: polyaniline, photograft, sol-gel, uv-curable polymer

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