Numerical simulation of localized cure of thermosensitive resin during thermo stereolithography process (TSTL)

In this work, to analyze a type of rapid prototyping technique, a numerical model was developed that was able to simulate the heat transfer at thermosensitive polymeric material during cure by laser irradiation. The analysis was carried out as a transient thermal problem using the general‐purpose finite element software ANSYS. The technique analyzed was thermal stereolithography, which uses a CO₂ laser beam to cure (solidify) thermosensitive liquid resins in a selective way to produce three‐dimensional parts. In this numerical analysis, the temperature distribution at thermoset material heated by a laser irradiation and its thermal properties are investigated. This resin is a high‐viscosity sample composed of epoxy resin, diethylenetriamine, and silica powder, which become highly crosslinked when irradiated by infrared laser. The localized curing becomes critical when the amount of silica and laser parameters are not appropriate. Bearing this in mind, this work intends, by applying the numerical method developed, to analyze the thermal behavior of resins in function of amount of silica and the laser radiation conditions, so that it is possible to have a knowledge on these variables so as to achieve a product with the required specifications. © 2006 Wiley Periodicals, Inc. J Appl PolymSci 102: 2777–2783, 2006     

面成型3D打印工艺中投影图像畸变校正技术

针对面成型工艺中视图发生器在投影时存在图像畸变的问题,提出一种畸变校正方案,通过图像处理获得投影平面像素点的实际坐标,将模型二维轮廓与像素实际坐标求交,并根据交点信息生成预畸变掩膜图像。同时在加工范围内分区域对不同位置的像素采用线性插值和双线性插值算法,对光辐照度进行均匀化处理。试验结果表明:采用本方案均匀化处理后的辐照度值,极差不超过0.4 mW/cm²,加工零件误差约为0.05 mm,能够有效控制畸变造成的影响,提高面成型工艺加工精度。     

Stabilization of tricalcium phosphate slurries against sedimentation for stereolithographic additive manufacturing and influence on the final mechanical properties

Ceramic parts manufactured by lithography‐based ceramic manufacturing (LCM) excel in resolution and surface quality. The material for LCM is a photosensitive ceramic particle‐filled slurry which needs to have homogeneous properties over time and during each processing step. The goal of this study was to use “mechanical” stabilization for a tricalcium phosphate‐filled slurry done by increasing slurry viscosity, solids loading, or inducing thixotropic behavior. The modified slurries were compared with a nonstable reference slurry. While all methods lead to increased storage stability, only the stabilized slurry with 0.5 wt% fumed silica is stable during the printing process.     

Surface modification of α-Al2O3 with dicarboxylic acids for the preparation of UV-curable ceramic suspensions

Stereolithography of UV-curable ceramic suspensions can benefit from the preparation of stable, low viscosity and high solid loading ceramic suspensions without yield stress. Appropriately adding dispersants could optimize the rheological behavior to meet the requirements of stereolithography. In this work, short-chain dicarboxylic acids were utilized to modify the alumina particles and achieve well dispersed ceramic suspensions. The maximum adsorption capacities of dicarboxylic acids were determined by the method of High Performance Liquid Chromatography and the mechanism of surface modification and dispersion was also discussed. Dicarboxylic acids’ influence on the rheology behavior was systematically studied. When doses of dicarboxylic acids reach their maximum adsorption capacities, the alumina suspensions would achieve their lowest viscosities and yield stresses. 45 vol% alumina suspension with a viscosity ˂2 Pa s at shear rate 30 s⁻¹ was successfully formulated. A sintering density of 96.5% can be achieved for the sebacic acid-modified alumina UV-curable suspension.     

基于遗传算法的光固化成形变形控制

原型件的变形是影响光固化成形精度的主要因素,制作参数的优化是减小变形的主要途径之一,但由于变形的影响因素复杂,变形机制尚不明确,所以这方面的研究进展缓慢.文章首先选取了影响变形的可控制作参数,采用Taguchi方法进行了实验研究, 根据实验数据建立了基于神经网络的变形评价模型,以此作为优化目标函数,提出了基于遗传算法实现约束条件下的多参数综合优化方案,并用于制作过程控制,试验证明可有效减小变形.     

Developments in investment casting process—A review

Investment casting has been used to manufacture weapons, jewellery and art castings during the ancient civilization. Today, its applications include jewellery/art castings, turbine blades and many more industrial/scientific components. The present paper reviews various investigations made by researchers in different stages of investment casting and highlights their importance. The paper initially highlights the investigations made on pattern wax properties, effects of blending, additives and fillers. Different ways through which pattern properties (like surface finish, dimensional accuracy, etc.) could be enhanced by properly controlling the injection processing parameters are thoroughly discussed. The paper also looks into the investigations made to enhance the strength, surface finish, etc. of ceramic shell for ferrous alloys/non-ferrous alloys as well as superalloys in investment casting. Investigations made on incorporation of nylon fibers and polymer additions confirm that a ceramic shell reinforced with nylon fibers attains additional permeability compared to the one with polymer additions.     

快速成型技术及其在微机械制造中的应用

本文介绍了快速成型技术的基本原理、典型的成型工艺及系统,以及快速成型在产品设计、快速制模、快速铸造、医疗工程、三维复制及打印等方面的应用;报道了快速成型技术在微机械制造中的应用实例.     

特种微型机械加工技术

综述微型机电系统/微型机械的三维形状加工及极限尺寸加工的研究开发现状.相对硅微细加工和LIGA工艺,不采用掩膜版的特种微细加工技术,如微细激光成型、微细电火花加工以及微细机械加工等近年来取得较大进展,在三维微小机械结构成型上有独到优势;同时扫描隧道显微加工技术的开发将微型机械向极限尺寸领域推进.微型机电系统/微型机械的长足发展有赖于融合已有先进技术和交叉学科思想的微型机械加工技术的进一步研究开发.     

陶瓷光固化技术及其应用

陶瓷材料因具有高硬度、高强度、耐高温、抗腐蚀等优异性能,被广泛应用于航空航天、生物医疗等领域,但是应用于上述领域的复杂结构陶瓷的制造仍然是一个重要的挑战。增材制造技术通过逐层堆积材料的方式来获得实体,在制造复杂结构陶瓷方面具有传统成形方式所无法比拟的优势。在众多陶瓷增材制造技术中,陶瓷光固化技术因其理想的成形质量而受到广泛关注和重视。在介绍立体光固化、数字光处理这两种主流陶瓷光固化技术的原理和特点的基础上,系统地介绍和分析了立体光固化技术和数字光处理技术的研究现状、应用以及存在的问题。最后,对陶瓷光固化技术及其应用进行了总结和展望。