Layer thickness and draft angle selection for stereolithography injection mould tooling

The introduction of rapid prototyping has allowed engineers and designers to generate physical models of required parts very early on in the design and development phase. Further to this, the use of stereolithography (SL) cavities as a rapid tooling method has allowed plastic prototype parts to be produced in their most common production manner -- by injection moulding. The process is best suited to small production runs where the high costs of conventionally machined tooling is prohibitive. One of the major drawbacks of the SL injectionmoulding process is the susceptibility of the tools to premature failure. SL tools may break under the force exerted by part ejection when the friction between a moulding and a core is greater than the tensile strength of the core, resulting in tensile failure. Very few justified recommendations exist about the choice of mould design variables that can lower the part ejection force experienced and reduce the risk of SL tool failure. This research investigates the ejection forces resulting from SL injection moulding tools which are identical in all respects except for their build layer thickness and incorporated draft angles in an attempt to identify appropriate evidence for recommendations with respect to these design variables and SL injection moulding. The results show that adjustment of draft angle results in a change of part ejection force as a reasonably linear relationship. An adjustment of the build layer thickness results in a change in part ejection force as a more non-linear relationship. The adjustment of build layer thickness had a greater effect on ejection force than the adjustment of draft angle. The results also show that the surface roughness of all tools remains unchanged after moulding a number of parts in polypropylene. A mathematical model was used in an attempt to predict ejection forces according to the moulding material used. This model reflected the experimental results in terms of relative values but not in absolute values, which may be due to inappropriate specific values used in their calculation. Finite element analysis (FEA) was used in an attempt to identify the factors involved in the ejection process. Results indicate that the effect of draft angle on ejection force is due to elastic deformation of the surface roughness. A fact borne out by the lack of damage to the surface after ejection.     

Survival of Salmonella Enteritidis PT 30 on inoculated almond kernels in hot water treatments

Almonds are blanched by exposure to hot water or steam-injected water to remove the pellicle (skin) from the kernel. This study evaluated the survival of Salmonella Enteritidis PT 30, Salmonella Senftenberg 775W and Enterococcus faecalis on whole raw almond kernels exposed to hot water. Whole, inoculated (7 to 9 log CFU/g) Nonpareil almonds (40 g) were submerged in 25 L of water maintained at 60, 70, 80 and 88 °C. Almonds were heated for up to 12 min, drained for 2 s, and transferred to 80 mL of cold (4 °C) tryptic soy broth. Almonds in broth were stomached at high speed for 2 min, serially diluted, plated onto tryptic soy and bismuth sulfite agars (Salmonella) or bile esculin agar (Enterococcus) and incubated at 37 °C for 24 and 48 h, respectively. D values of 2.6, 1.2, 0.75 and 0.39 min were calculated for exposure of S. Enteritidis PT 30 to water at 60, 70, 80 and 88 °C, respectively; the calculated z value was 35 C°. D values determined for Salmonella Senftenberg 775W and E. faecalis at 88 °C were 0.37 and 0.36 min, respectively. Neither Salmonella serovar could be recovered by enrichment of 1-g samples after almonds inoculated at 5 log CFU/g were heated at 88 °C for 2 min. These data will be useful to validate almond industry blanching processes.     

Seismic damage and fragility analysis of structures with tuned mass dampers based on plastic energy

The effectiveness of using a tuned mass damper (TMD) to improve a structure's ability to dissipate earthquake input energy is investigated through the use of seismic fragility curves. The nonlinear material behaviour of the structure is captured using the force analogy method, the backbone for analytically quantifying plastic energy dissipation in the structure. Numerical analysis was performed to study the global response and local energy dissipation of a six‐storey moment‐resisting steel frame with and without a TMD installed for 100 simulated non‐stationary Gaussian earthquake ground motions. The effectiveness of the TMD, based on reduction of seismic responses and enhancement of the seismic fragility, is considered at structural performance levels for immediate occupancy and life safety as identified in FEMA 440. An ‘equivalent monotonic plastic strain’ approach—a local measure of structural damage—is used to correlate the seismic fragilities at different global performance levels based on storey drift. Results illustrate that a TMD can enhance the structure's ability to dissipate energy at low levels of earthquake shaking, while less effective during moderate to strong earthquakes, which can cause a significant period shift associated with major structural damage. This ‘de‐tuning’ effect suggests that an extremely sizable TMD is not effective in reducing damage of a structure. Published in 2010 by John Wiley & Sons, Ltd.     

A hyperbolic augmented elasto-plastic model for pressure-dependent yield

A three-dimensional elasto-plastic model for the deformation and flow of granular materials which generalises the plastic potential model and contains an additional term analogous to that appearing in the double-shearing model is presented. It is shown that for planar flows the resulting system of first-order partial differential equations is hyperbolic. This is in distinct contrast to both the non-associated plastic potential and double-shearing models, which fail to be hyperbolic. The ill-posedness of the Cauchy problem for the planar double-shearing model is due to the presence of the rotation rate of the principal axes of stress while that of the non-associated plastic potential model is due to distinct quasi-static spatial stress and velocity characteristics. The present model attains well-posedness by replacing the planar rotation rate of the principal stress axes by the vector intrinsic spin of a Cosserat continuum and using it to ensure identical spatial stress and velocity characteristics. Flows in which the intrinsic spin vector is constant in both space and time correspond to flows in an ordinary continuum. The model governing such flows is embedded into a Cosserat model in such a way that the characteristic structure is preserved.     

Drop printing of pharmaceuticals: Effect of molecular weight on PEG coated‐naproxen/PEG 3350 solid dispersions

Solid dispersions have been used to enhance the bioavailability of poorly water‐soluble active pharmaceutical ingredients (APIs). However, the solid‐state phase, compositional uniformity, and scale‐up problems are issues that need to be addressed. To allow for highly controllable products, the drop printing (DP) technique can provide precise dosages and predictable compositional uniformity of APIs in two‐/three‐dimensional structures. DP was used to prepare naproxen (NAP)/polyethylene glycol 3350 (PEG 3350) solid dispersions with PEG coatings of different molecular weights (MWs). A comparison of moisture‐accelerated crystallization inhibition by different PEG coatings was assessed. Scanning electron microscopy, second harmonic generation microscopy, and differential scanning calorimetry analysis were performed to characterize the morphology and quantify the apparent crystallinity of NAP within the solid dispersions. Thermogravimetric analysis was employed to measure the water content within each sample. The results suggest that the moisture‐accelerated crystallization inhibition capability of the PEG coatings increased with increasing MW of the PEG coating. Besides, to demonstrate the flexibility of DP technology on manufacturing formulation, multilayer tablets with different PEG serving as barrier layers were also constructed, and their dissolution behavior was examined. By applying DP and appropriate materials, it is possible to design various carrier devices used to control the release dynamics of the API. © 2015 American Institute of Chemical Engineers AIChE J, 61: 4502–4508, 2015