Optimization of fused deposition modeling process parameters:a review of current research and future prospects

Fused deposition modeling(FDM) is one of the most popular additive manufacturing technologies for various engineering applications.FDM process has been introduced commercially in early 1990 s by Stratasys Inc.,USA.The quality of FDM processed parts mainly depends on careful selection of process variables.Thus,identification of the FDM process parameters that significantly affect the quality of FDM processed parts is important.In recent years,researchers have explored a number of ways to improve the mechanical properties and part quality using various experimental design techniques and concepts.This article aims to review the research carried out so far in determining and optimizing the process parameters of the FDM process.Several statistical designs of experiments and optimization techniques used for the determination of optimum process parameters have been examined.The trends for future FDM research in this area are described.     

An integral approach for simulation of vapour film dynamics around a spherical surface

The dynamics of a thermally driven vapour film around a solid sphere has been investigated here with both the sphere and the annular film surrounded by a large water pool. Integral models based on constant and variable vapour-phase densities have been developed here for studying a spherico-symmetric phase change problem for two immiscible phases, vapour and liquid around a hot sphere. Governing equations for both liquid and vapour phases are converted into a set of non-linear ODEs. Effects of distinct density on interface condition and density variation of vapour phase are taken into account both in energy equation of vapour phase and also in interfacial mass and energy balance. The present models have been validated with available analytical, incompressible Volume of Fluid (VOF) and experimental results of growth and collapse of either bubble or vapour film. A simple model, based on scale analysis, was evolved that successfully captured the non-monotonic growth of the film, as observed by the more detailed models under certain degree of liquid subcooling. In addition, the case of very small thermal boundary layer in the liquid side has been successfully studied for which the VOF model required very fine grid. It has been observed that the effect of density variation in the integral model results in marginally higher film growth at higher temperature. However, the effect of radiation on the film growth was found to be quite substantial. The integral model not only incorporates the effects of vapour-phase temperature variation and radiation exchange of heat but also is computationally several-fold efficient with respect to the VOF model.     

Identification of faults through wavelet transform vis-à-vis fast Fourier transform of noisy vibration signals emanated from defective rolling element bearings

Fault diagnosis of rolling element bearings requires efficient signal processing techniques. For this purpose, the performances of envelope detection with fast Fourier transform (FFT) and continuous wavelet transform (CWT) of vibration signals produced from a bearing with defects on inner race and rolling element, have been examined at low signal to noise ratio. Both simulated and experimental signals from identical bearings have been considered for the purpose of analysis. The bearings have been modeled as spring-mass-dashpot systems and the simulated signals have been obtained considering transfer functions for the bearing systems subjected to impulsive loads due to the defects. Frequency B spline wavelets have been applied for CWT and a discussion on wavelet selection has been presented for better effectiveness. Results show that use of CWT with the proposed wavelets overcomes the short coming of FFT while processing a noisy vibration signals for defect detection of bearings.     

Seismic reliability of non-linear frames with PR connections using systematic RSM

An effective, efficient, and robust reliability analysis algorithm is proposed for non-linear structures, where seismic loading can be applied in the time domain. The method is developed specifically for steel frame structures considering all major sources of non-linearity, including geometry, material, and partially restrained (PR) connections. The non-linearity due to PR connections is modeled by moment-relative rotation curves using the four-parameter Richard model. For seismic excitation, the loading, unloading, and reloading behavior at PR connections is modeled using moment-relative rotation curves and the Masing rule. The proposed algorithm intelligently integrates the response surface method, the finite element method, the first-order reliability method, and an iterative linear interpolation scheme. The uncertainties in all the random variables including the four parameters of Richard model are considered. Two unique features of the proposed algorithm are that (1) actual earthquake time histories can be used to excite structures in the presence of major sources of non-linearity and uncertainty and (2) it is possible to estimate the risk corresponding to both the serviceability and strength limit states. The algorithm is verified using the Monte Carlo simulation technique. The verified algorithm is first used to study the reliability of a frame structure in the presence of PR connections with different degrees of flexibility. Then the algorithm is used to estimate the reliability of a frame structure excited by 13 actual recorded earthquake time histories, 12 of them recorded during the Northridge earthquake of 1994. As expected, the reliabilities of the frame are found to be quite different, when excited by several time histories of the Northridge earthquake.     

Computational thermodynamics in electric current metallurgy

Abstract

A priori derivation for the extra free energy caused by the passing electric current in metal is presented. The analytical expression and its discrete format in support of the numerical calculation of thermodynamics in electric current metallurgy have been developed. This enables the calculation of electric current distribution, current induced temperature distribution and free energy sequence of various phase transitions in multiphase materials. The work is particularly suitable for the study of magnetic materials that contain various magnetic phases. The latter has not been considered in literature. The method has been validated against the analytical solution of current distribution and experimental observation of microstructure evolution. It provides a basis for the design, prediction and implementation of the electric current metallurgy. The applicability of the theory is discussed in the derivations.     

Electropulse-induced cementite nanoparticle formation in deformed pearlitic steels

Passing one electric current pulse through deformed pearlitic steel wires at room temperature causes the formation of cementite particles around 30 nm in size. This is found not only in some particular locations but throughout the cementite area, which reveals a different mechanism from traditional spheroidization of cementite plates because the latter leads to the formation of particles with much large size. Transmission electron microscopy images show electropulse-induced strain relief and formation of fine precipitations. Differential scanning calorimetry analysis demonstrates the additional stored free energy by electropulsing treatment. The raised free energy accounts the increased interface area in finer microstructure of materials. The experiment evidences that the passing electric current in metal has alternated the free energy sequence of various microstructures in comparison with that of current-free system.     

Experimental investigation of spray characteristics of kerosene and ethanol-blended kerosene using a gas turbine hybrid atomizer

Gas turbines have wide application as prime movers in transportation and power generating sectors, most of which are driven by fossil fuels like kerosene. The conventional fuels are associated with problems of air pollution, and the fuel reserves are getting depleted gradually. Addition of ethanol in kerosene leads to better spraying characteristics. The present work deals with the spray characteristics of pure kerosene and 10%-ethanol-blended (by volume) kerosene using a novel gas-turbine hybrid atomizer. Here the inner air and outer air enter in the same and opposite directions, respectively, with respect to the fuel flow direction into the atomizer and a high swirling effect occurs outside the nozzle. The fuel stream is sandwiched between two annular air streams and the flow rate of inner and outer air is varied continuously. Various spray stages like distorted pencil, onion, tulip and fully developed spray regimes have been observed. The breakup length, cone angle and sheet width of the fuel stream are analysed directly from backlit imaging for different fuel and air flow rates. From the image processing, it is observed that breakup occurs at an early stage for 10%-ethanol-blended kerosene due to low viscosity of ethanol. It is also observed that at higher air flow rate, breakup occurs at an early stage due to turbulent nature of the fuel stream.     

Time-domain seismic reliability of nonlinear structures

A novel reliability analysis technique is presented to estimate the reliability of real structural systems. Its unique feature is that the dynamic loadings can be applied in time domain. It is a nonlinear stochastic finite element logarithm combined with the response surface method (RSM). It generates the response surface around the most probable failure point and incorporates information of the distribution of the random variables in the RSM formulation. It is verified using the Monte Carlo simulation technique, and is found to be very efficient and accurate. Most sources of nonlinearlity and uncertainty can be explicitly incorporated in the formulation. The flexibility of connections, represented by moment-relative rotation(M-θ) curves, is addressed. After the Northridge earthquake of 1994, several improved steel connections were proposed. Structural Sesimic Design Associates (SSDA) tested several full-scale proprietory slotted web beam-column connections. The authors suggested(M-θ) curves for this connection using actual test data. Behaviours of steel frames, assuming the connections are fully restrained, partially restrained, consisting of pre and post-Northridge connections are evaluated and compared. Desirable features of the post-Northridge connections observed during testing are analytically confirmed. Laterally weak steel frame is then strengthened with concrete shear walls. Capabilities and the advanced nature of the method are demonstrated with the help of realistic examples. This paper is dedicated to Prof R N Iyengar of the Indian Institute of Science on the occasion of his formal retirement.