Mechanical Engineering Commons^™

Design, Analysis, And Application Of A Cellular Material/Structure Model For Metal Based Additive Manufacturing Process., Shanshan Zhang

Electronic Theses and Dissertations

Powder bed fusion additive manufacturing (PBF-AM) has been broadly utilized to fabricate lightweight cellular structures, which have promising potentials in many engineering applications such as biomedical prosthesis, aerospace, and architectural structures due to their high performance-to-weight ratios and unique property tailorabilities. To date, there is still a lack of adequate understanding of how the cellular materials are influenced by both the geometry designs and process parameters, which significantly hinders the effective design of cellular structures fabricated by PBF-AM for critical applications. This study aims to demonstrate a cellular structure design methodology that integrates geometrical design and process-material property designs. Utilizing …

Material Properties Design Using Simulations And Experiments For Powder Injection Molding Of Lead Zirconate Titanate (Pzt)., Bhushan Pramod Bandiwadekar

Electronic Theses and Dissertations

Powder injection molding (PIM) process simulations can be performed to minimize the number of injection molding experiments by estimating material properties necessary for PIM simulations. In current work, lead zirconate titanate (PZT) powder-polymer binder feedstock was compounded for 45 vol. % and 52 vol. % solids loading. PIM experiments on designed micro-pillar array geometry were performed using 52 vol. % PZT. Using PIM experiments results as basis, PIM simulations were performed on designed micro-pillar array geometries to understand the effectiveness of PIM simulations with the use of estimated feedstock properties in predicting molding behavior that have micro-features. Additionally, PIM simulations …

Feasibility Of Using 3d Printed Molds For Thermoforming Thermoplastic Composites, Sunil Bhandari

Electronic Theses and Dissertations

This thesis presents a novel combined experimental and numerical mechanics approach for characterizing 3D printed thermoplastic materials by the fused deposition modeling process for thermoforming thermoplastic composites. The implications of this work are:

1. a methodology for model-based performance evaluation of 3D printed structural parts, and
2. an improved design of 3D printed molds for composites manufacturing, which has potential for material innovations and scaled-up applications in additive manufacturing.

The thesis formulates basic criteria for selection of thermoplastic polymer used for the 3D printed mold based on forming temperatures. The thesis creates a lattice and shell finite element model of the 3D …

Variable Oxidation & Defects In Ti-6al-4v Material In Electron Beam Melting Additive Manufacturing, Edward Patton Clark

Electronic Theses and Dissertations

Powder-based metal in additive manufacturing (AM) is advantageous for rapid prototyping of parts and components, with the benefit of reusing powder to reduce production costs. A common driver in the aerospace industry is free-form complex geometries which can be created using CAD software to optimize specifications with strength-to-weight ratios in components. Weight optimization of aircraft components using additive manufacturing reduces material, which significantly reduces production cost in comparison to cast and wrought metallic products. Large biomedical and aerospace industries heavily invest in feedstock metal powders that have low density under structural stresses and high temperatures, resulting in superior resistance to …

Bio Inspired Lightweight Composite Material Design For 3d Printing, Kaushik Thiyagarajan

Electronic Theses and Dissertations

Lightweight material design is an indispensable subject in product design. The lightweight material design has high strength to weight ratio which becomes a huge attraction and an area of exploration for the researchers as its application is wide and increasing even in every day-to-day product. Lightweight composite material design is achieved by selection of the cellular structure and its optimization. Cellular structure is used as it has wide multifunctional properties in addition to the lightweight characteristics. Applications of light weight cellular structures are wide and is witnessed in all industries from aerospace to automotive, construction to product design. In this …