Additive Manufacturing Hybrid Processes for Composites Systems (Advanced Structured Materials, 129)

✍ Scribed by António Torres Marques (editor), Sílvia Esteves (editor), João P. T. Pereira (editor), Luis Miguel Oliveira (editor)

• Publisher: Springer
• Year: 2020
• Tongue: English
• Leaves: 346
• Edition: 1st ed. 2020
• Category: Library

✦ Synopsis

This book focuses on the emerging additive manufacturing technology and its applications beyond state-of-the-art, fibre-reinforced thermoplastics. It also discusses the development of a hybrid, integrated process that combines additive and subtractive operations in a single-step platform, allowing CAD-to-Part production with freeform shapes using long or continuous fibre-reinforced thermoplastics. The book covers the entire value chain of this next-generation technology, from part design and materials composition to transformation stages, product evaluation, and end-of-life studies.

Moreover, it addresses the following engineering issues:

• Design rules for hybrid additive manufacturing;

• Thermoplastic compounds for high-temperature and -strength applications;

• Advanced extrusion heads and process concepts;

• Hybridisation strategies;

• Software ecosystems for hAM design, pre-processing, process planning, emulating and multi-axis processing;

• 3D path generators for hAM based on a multi-objective optimisation algorithm that matches the recent curved adaptive slicing method with a new transversal scheme;

• hAM parameters, real-time monitoring and closed-loop control;

• Multiparametric nondestructive testing (NDT) tools customised for FRTP AM parts;

• Sustainable manufacturing processes validated by advanced LCA/LCC models.

✦ Table of Contents

Preface
Contents
Acronyms
Symbols and Units
1 State-of-the-Art Review and Roadmap
1.1 Materials, Processes and Applications Mapping
1.1.1 Scientific Status
1.1.2 Major Challenges and Opportunities
1.1.3 Gaps, Barriers and Bottleneck to be Solved
1.1.4 Conclusions
1.2 New Strategies for AM FRTP Parts Performance Improvement
1.2.1 Scientific Status
1.2.2 Major Challenges and Opportunities
1.2.3 Gaps, Barriers and Bottleneck to Be Solved
1.2.4 Conclusions
1.3 FRTP Parts Certification and Quality Assurance
1.3.1 Scientific Status
1.3.2 Major Challenges and Opportunities
1.3.3 Gaps, Barriers and Bottleneck to Be Solved
1.3.4 Conclusions
1.4 LCA/LCC of Composite Materials
1.4.1 Scientific Status
1.4.2 Major Challenges and Opportunities
1.4.3 Gaps, Barriers and Bottleneck to be Solved
1.4.4 Conclusions
1.5 AM and Composites Research Roadmap
1.5.1 Composite Additive Manufacturing Research Roadmap
1.5.2 Industry Targets and Societal Impact
1.5.3 Conclusions
References
2 Design and Modelling Approaches
2.1 Introduction
2.2 Design for Hybrid AM
2.2.1 Definition and Classification of Hybrid AM
2.2.2 Hybrid AM Manufacturing Systems
2.2.3 Hybrid AM Combining CNC Machining and FDM
2.2.4 Case Studies with Hybrid AM with CNC Machining of FDM Parts
2.3 Multifunctional and Graded Features (MFG)
2.3.1 What Are Multifunctional and Graded Materials. Why Their Use?
2.3.2 When and Where to Use MFG by AM
2.3.3 How to Design and Print MFG?—Case Studies
2.4 Design Methodologies, Modelling and Tools
2.4.1 Design Methodologies for Hybrid AM
2.4.2 Modelling for Hybrid AM
2.4.3 Simulation Tools for Hybrid AM
2.5 Sustainability Assessment in AM-Related Processes
2.5.1 Challenges of AM-Related Technologies in Sustainability Dimensions
2.5.2 Proposed Approach for Life Cycle-Based Sustainability Assessment
2.5.3 Economic Assessment
2.5.4 Environmental Assessment
2.5.5 Social Assessment
2.5.6 Major Challenges and Opportunities
References
3 New Material Concepts
3.1 Introduction
3.2 Material Concepts and Composition
3.2.1 Characterization of Commercial Filaments
3.2.2 Summary of Main Results
3.3 Reinforcements Impregnation
3.3.1 Development of PEEK and PA66 Formulations
3.3.2 Filaments Processing
3.4 Material Concepts Validation
3.4.1 Characterization of PEEK and PA66 Formulations
3.4.2 Summary of Main Results
3.4.3 Formulation Processing Requirements for AM
3.4.4 Materials for Optical Fibre Sensors
3.4.5 Materials for Nitinol Fibre Reinforcement
3.5 Conclusions
References
4 New Process Concepts: Composites Processing
4.1 Design and Development of a Prototype Extrusion Head
4.2 Numerical Assessment
4.2.1 Heat Transfer Simulations
4.2.2 Simulation Conditions
4.2.3 Results and Discussion
4.3 Computational Fluid Dynamics Simulations
4.3.1 Governing Equations
4.3.2 Computational Details
4.3.3 Results and Discussion
4.4 Extrusion Head Improvements
4.4.1 Overview and Specifications
4.4.2 Concept Design
4.4.3 Concluding Remarks
4.5 Hybridization and Deposition Strategies and Paths
4.5.1 Experimental Work—Full Factorial DOE Approach
4.5.2 Experimental Procedure
4.5.3 Results and Discussion
4.5.4 Deposition Strategies
4.6 Process Concepts Validation
4.6.1 Experimental Assessment of the First Prototype Extrusion Head
4.6.2 Definitions and Equipment and Materials
4.6.3 FDM Machine Control
4.6.4 Processability of a Composite Filament—Preliminary Appreciation
4.6.5 Concluding Remarks
4.7 Proposal
References
5 Systems Design for FRP Hybrid AM
5.1 Introduction to Hybrid Machines
5.2 AM Capable Technologies Suited for Hybrid Processes
5.2.1 Fused Deposition Modeling (FDM)
5.2.2 Direct Energy Deposition (DED)
5.2.3 AM Relative to Other Processes
5.3 Hybrid Systems and Additive Manufacturing as a Tool for Design for AM—Key Approaches
5.3.1 Strategy for DfAM
5.3.2 Methods for Choosing Components for AM
5.3.3 Design Rules for AM
5.4 Experimental Hybrid Systems in FDM/FFF—the FIBR3D Case Study
5.4.1 Preliminary Studies—Machine Design and Workflow
5.4.2 Experimental Rig Setup—Specifications and System Architecture
5.4.3 Experimental Hybrid System—Specifications and System Architecture
5.5 Platform Validation—Sample Prints and Conclusions
References
6 Path Generation, Control, and Monitoring
6.1 Optimal Orientation of Objects
6.1.1 Measuring Printing Quality
6.1.2 A Global Optimization Approach
6.1.3 A Multi-objective Optimization Approach
6.2 5-Axis Printer and Emulator—Graphics Emulator Tool—FIBR3DEmul
6.2.1 FDM Simulation
6.2.2 The Virtual C3DPrinter
6.2.3 Printer Control
6.2.4 Results and Discussion
6.3 Curved Path Planning
6.3.1 Curved Layer Manufacturing
6.4 Printing Complex Objects
6.4.1 Complex Objects Printing Approach
6.4.2 Heuristic to Obtain an Optimal Building Sequence
6.4.3 Results
6.5 Non-destructive Inspection Path Planning
References
7 Experimental Testing and Process Parametrization
7.1 Introduction
7.2 Experimental
7.2.1 Material Filaments
7.2.2 Material Properties
7.2.3 Experimental Methodology for FDM Printing
7.3 Results and Discussion
7.3.1 Tensile Testing Samples
7.3.2 DCB Samples
7.4 Conclusions
References
8 Reliability and NDT Methods
8.1 Defects in Additive Manufacturing of Composites
8.2 Non-destructive Testing Techniques for AM of Composites
8.2.1 Ultrasound
8.2.2 X-ray
8.2.3 Thermography
8.2.4 Eddy Currents
8.2.5 Optical-Based NDT
8.2.6 Overview of NDT Techniques
8.3 Numerical Simulation in NDT: State of the Art
8.3.1 Thermography
8.3.2 Ultrasound
8.3.3 Eddy Currents
8.3.4 Other Techniques
8.4 Experimental Validation of NDT
8.4.1 Standard Defects Production
8.4.2 Eddy Currents
8.4.3 Immersion Ultrasound
8.4.4 X-ray
8.4.5 Thermography
8.4.6 Combined Thermography and Optical Fibre Hybrid Sensors Analysis of Thermal Evolution Inside a Composite
8.4.7 3D Scanning Device for NDT
8.4.8 Characterization Techniques of 3D Scanning Device
8.5 Thermography NDT Module
8.6 Ultrasound Air-Coupled NDT Module
8.7 Conclusions
References
9 Case Studies
9.1 Introduction
9.2 Case Study Selection Criteria
9.2.1 Motivation
9.3 Case Study Presentation
9.3.1 Problem Statement and Simulation
9.3.2 Analysis of TO Results
9.4 Critical Analysis and Conclusions
References
10 Development of a Constitutive Model to Predict the Elasto-Plastic Behaviour of 3D-Printed Thermoplastics: A Meshless Formulation
10.1 Introduction
10.2 The RPIM—Radial Point Interpolation Method
10.2.1 Meshless Generic Procedure
10.2.2 RPI Shape Functions
10.2.3 Meshless System of Equations for Linear Static Problems
10.3 Elasto-Plastic Formulation
10.3.1 Modified Hill Yield Criterion
10.3.2 Constitutive Model
10.4 Numerical Examples
10.4.1 Uniaxial Tensile and Compression Tests
10.4.2 Benchmark: Cantilever Beam Problem
10.4.3 Conclusions
References