Browsing by Subject "additive manufacturing (AM)"
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Item Machine Learning Enabled Powder Spreading Process Map for Metal Additive Manufacturing (AM)(University of Texas at Austin, 2017) Zhang, Wentai; Mehta, Akash; Desai, Prathamesh S.; Higgs, C. Fred IIIThe metal powder-bed AM process involves two main steps: the spreading of powder layer and selective fusing or binding the spread layer. Most AM research is focused on powder fusion. Powder spreading is more rarely studied but is of significant importance for considering the quality of the final part and total build time. It is thus essential to understand how to modify the spread parameters such as spreader speed, to generate layers with desirable roughness and porosity. A computational modeling framework employing Discrete Element Method (DEM) is applied to simulate the spreading process, which is difficult to study experimentally, of Ti-6Al-4V powder onto smooth substrates. Since the DEM simulations are computationally expensive, machine learning was employed to interpolate between the highly non-linear results obtained by the running a few DEM simulations. Eventually, a spreading process map is generated to determine which spreader parameters can achieve the desired surface roughness and spread speed. This eventually saves the total time for printing and reduces the cost of build.Item Optimal Design of a Golf Club using Functionally Graded Porosity(University of Texas at Austin, 2011-08-17) Ray, Phillip; Chahine, Gilbert; Smith, Pauline; Kovacevic, R.The current work portrays a new concept of designing and manufacturing golf club heads with functionally graded porosity (FGP) by means of electron beam melting® (EBM®). In light of the advancement of additive manufacturing (AM) technologies and the consequent wide spread applications in the aerospace, automotive, and biomedical industries, the current work discusses a new application in sport technologies; for example, in the golf industry. EBM® makes it possible to print the designed porosity within a golf club head, to reduce the weight and optimize performance. The focus is to design the golf club head with FGP to improve performance and reduce weight. The dynamic properties of porous materials are investigated theoretically. The porosity in the club head was analyzed numerically by simulating the impact between the club head and a steel ball in order to determine the coefficient of restitution (COR) of the club head. The simulation’s parameters are in compliance with the U.S Golf Association’s (USGA) test procedure for measuring COR.Item Remanufacture of Turbine Blades by Laser Cladding, Machining and In-Process Scanning in a Single Machine(University of Texas at Austin, 2012-08-16) Jones, Jason; McNutt, Phil; Tosi, Riccardo; Perry, Clinton; Wimpenny, DavidRemanufacturing is one of the most efficient ways of recycling worn parts because it consumes only a fraction of the energy, cost, and material required for new parts. Remanufacture of engineering components typically entails serial labor intensive and operator skill sensitive processes, often requiring parts to move between manufacturers and subcontractors. Unfortunately the logistics and quality assurance measures required for effective remanufacturing currently restrict its implementation primarily to high value components (e.g. turbine blades, blisks, etc.). This research reports progress toward an integrated production system which combines laser cladding, machining and in-process scanning in a single machine for flexible and lean remanufacturing.