Anisotropic Mechanical Properties of ABS Parts Fabricated by Fused Deposition Modelling

In recent years, layered manufacturing (LM) processes have begun to progress from rapid prototyping techniques towards rapid manufacturing methods, where the objective is now to produce finished components for potential end use in a product (Caulfield et al., 2007). LM is especially promising for the fabrication of specific need, low volume products such as replacement parts for larger systems. This trend accentuates the need for a thorough understanding of the associated mechanical properties and the resulting behavior of parts produced by layered methods. Not only must the base material be durable, but the mechanical properties of the layered components must be sufficient to meet in-service loading and operational requirements, and be reasonably comparable to parts produced by more traditional manufacturing techniques. This chapter presents the details of a study completed to quantitatively analyze the potential of fused deposition modelling to fully evolve into a rapid manufacturing tool. The project objective is to develop an understanding of the dependence of the mechanical properties of FDM parts on raster orientation and to assess whether these parts are capable of maintaining their integrity while under service loading. The study examines the effect of fiber orientation, i.e. the direction of the polymer beads relative to the loading direction of the part, on a variety of important mechanical properties of ABS components fabricated by fused deposition modeling. Tensile, compressive, flexural, impact, and fatigue strength properties of FDM specimens are examined, evaluated, and placed in context in comparison with the properties of injection molded ABS parts.

Organizational and direct support maintenance repair parts and special tools lists for generator, smoke, mechanical, pulse jet, M3A4 (1040-01-143-9506).

"June 1989."

Organizational maintenance repair parts and special tools list : refrigeration unit, mechanical, panel type, gasoline engine driven, 9000 Btu, type I, for semitrailer, refrigerator, 7 1/2 ton (Redmanson model RGP-9000), NSN 4110-00-935-1512 ....

"March 1976."

Organizational, direct support, and general support maintenance repair parts and special tools lists ... for refrigeration unit, mechanical, panel type, 10,000 Btu/hr, electric motor driven, model-REMD-K/II-10LS, NSN 4110-01-163-2140.

"3 March 1987."

Manufacturing challenges with fabrication of large size mechanical harmonic drives

In truck manufacturing, the exhaust and air inlet pipes are specialized equipment that requires highly skilled, heavy machinery and small batch production methods. This paper describes a project to develop the computer numerically controlled (CNC) pipe bending process for a truck component manufacturer. The company supplies a huge range of heavy duty truck parts to the domestic market and is a significant supplier in Australia. The company has been using traditional methods of machine assisted manual pipe bending techniques. In a drive of continuous improvement, the company has acquired a pre-owned CNC bending machine capable of bending pipes automatically up to 25 bends. However, due to process mismatch, this machine is only used for single bending operation. The researchers studied the bending system and changed the manufacturing process. Using an example exhaust pipe as the benchmark, a significant drop of manufacturing lead time from 70 minutes to 40 minutes for each pipe was demonstrated. There was also a decrease of material cost due to the multiple bends part in one piece without cutting excessive materials for each single bend like it used to be.

Manufacturing challenges with fabrication of large size mechanical harmonic drives

Mechanical harmonic transmissions are relatively new kind of drives having several unusual features. For example, they can provide reduction ratio up to 500:1 in one stage, have very small teeth module compared to conventional drives and very large number of teeth (up to 1000) on a flexible gear. If for conventional drives manufacturing methods are well-developed, fabrication of large size harmonic drives presents a challenge. For example, how to fabricate a thin shell of 1.7m in diameter and wall thickness of 30mm having high precision external teeth at one end and internal splines at the other end? It is so flexible that conventional fabrication methods become unsuitable. In this paper special fabrication methods are discussed that can be used for manufacturing of large size harmonic drive components. They include electro-slag welding and refining, the use of special expandable devices to locate and hold a flexible gear, welding peripheral parts of disks with wear resistant materials with subsequent machining and others. These fabrication methods proved to be effective and harmonic drives built with the use of these innovative technologies have been installed on heavy metallurgical equipment and successfully tested.

Growth of koster’s curse (Clidemia hirta) from seedlings to reproductive maturity and following mechanical damage

Koster´s curse is a highly invasive, perennial shrub with potential to become a major weed in many parts of Queensland and elsewhere in Australia. Presently, there is one infestation discovered in Australia and the species is a Class 1 weed. It grows to 5 m and can produce over 500 berries annually which are dispersed by birds and water. This study quantified growth and the effects of damage on survival and time to reproduction under both field and shade house conditions in the Wet Tropics of north Queensland. Plants recovered to their original size and were capable of setting seed in as few as 86 days and 194 days after being cut back to 10 cm and 0 cm respectively.

Automated inspection of aircraft parts using a modified ICP algorithm

The application of computer-aided inspection integrated with the coordinate measuring machine and laser scanners to inspect manufactured aircraft parts using robust registration of two-point datasets is a subject of active research in computational metrology. This paper presents a novel approach to automated inspection by matching shapes based on the modified iterative closest point (ICP) method to define a criterion for the acceptance or rejection of a part. This procedure improves upon existing methods by doing away with the following, viz., the need for constructing either a tessellated or smooth representation of the inspected part and requirements for an a priori knowledge of approximate registration and correspondence between the points representing the computer-aided design datasets and the part to be inspected. In addition, this procedure establishes a better measure for error between the two matched datasets. The use of localized region-based triangulation is proposed for tracking the error. The approach described improves the convergence of the ICP technique with a dramatic decrease in computational effort. Experimental results obtained by implementing this proposed approach using both synthetic and practical data show that the present method is efficient and robust. This method thereby validates the algorithm, and the examples demonstrate its potential to be used in engineering applications.

AIWIN - A fast and jigless inspection technique for machined parts

Precision inspection of manufactured components having multiple complex surfaces and variable tolerance definition is an involved, complex and time-consuming function. In routine practice, a jig is used to present the part in a known reference frame to carry out the inspection process. Jigs involve both time and cost in their development, manufacture and use. This paper describes 'as is where is inspection' (AIWIN), a new automated inspection technique that accelerates the inspection process by carrying out a fast registration procedure and establishing a quick correspondence between the part to inspect and its CAD geometry. The main challenge in doing away with a jig is that the inspection reference frame could be far removed from the CAD frame. Traditional techniques based on iterative closest point (ICP) or Newton methods require either a large number of iterations for convergence or fail in such a situation. A two-step coarse registration process is proposed to provide a good initial guess for a modified ICP algorithm developed earlier (Ravishankar et al., Int J Adv Manuf Technol 46(1-4):227-236, 2010). The first step uses a calibrated sphere for local hard registration and fixing the translation error. This transformation locates the centre for the sphere in the CAD frame. In the second step, the inverse transformation (involving pure rotation about multiple axes) required to align the inspection points measured on the manufactured part with the CAD point dataset of the model is determined and enforced. This completes the coarse registration enabling fast convergence of the modified ICP algorithm. The new technique has been implemented on complex freeform machined components and the inspection results clearly show that the process is precise and reliable with rapid convergence. © 2011 Springer-Verlag London Limited.

Effect of dentin tubules on the mechanical properties of dentin - part III: Numerical, analysis

Imitating a real tooth and the periodontal supporting tissues, we have established a 2D finite element model and carried out a numerical analysis based on the inhomogeneous and anisotropic (IA) stress-strain relation and strength model of dentin proposed in the preceding Parts I and II, and the conventional homogeneous and isotropic (III) model, respectively. Quite a few cases of loadings for a non-defected and a defected tooth are considered. The numerical results show that the stress level predicted by the IA model is remarkably higher than that by the III model, revealing that the effect of the dentin tubules should be taken into a serious consideration from the viewpoint of biomechanics.

Mechanical and leaching behaviour of slag-cement and lime-activated slag stabilised/solidified contaminated soil.

Stabilisation/solidification (S/S) is an effective technique for reducing the leachability of contaminants in soils. Very few studies have investigated the use of ground granulated blast furnace slag (GGBS) for S/S treatment of contaminated soils, although it has been shown to be effective in ground improvement. This study sought to investigate the potential of GGBS activated by cement and lime for S/S treatment of a mixed contaminated soil. A sandy soil spiked with 3000mg/kg each of a cocktail of heavy metals (Cd, Ni, Zn, Cu and Pb) and 10,000mg/kg of diesel was treated with binder blends of one part hydrated lime to four parts GGBS (lime-slag), and one part cement to nine parts GGBS (slag-cement). Three binder dosages, 5, 10 and 20% (m/m) were used and contaminated soil-cement samples were compacted to their optimum water contents. The effectiveness of the treatment was assessed using unconfined compressive strength (UCS), permeability and acid neutralisation capacity (ANC) tests with determination of contaminant leachability at the different acid additions. UCS values of up to 800kPa were recorded at 28days. The lowest coefficient of permeability recorded was 5×10(-9)m/s. With up to 20% binder dosage, the leachability of the contaminants was reduced to meet relevant environmental quality standards and landfill waste acceptance criteria. The pH-dependent leachability of the metals decreased over time. The results show that GGBS activated by cement and lime would be effective in reducing the leachability of contaminants in contaminated soils.

SketchIT: A Sketch Interpretation Tool for Conceptual Mechanical Design

We describe a program called SketchIT capable of producing multiple families of designs from a single sketch. The program is given a rough sketch (drawn using line segments for part faces and icons for springs and kinematic joints) and a description of the desired behavior. The sketch is "rough" in the sense that taken literally, it may not work. From this single, perhaps flawed sketch and the behavior description, the program produces an entire family of working designs. The program also produces design variants, each of which is itself a family of designs. SketchIT represents each family of designs with a "behavior ensuring parametric model" (BEP-Model), a parametric model augmented with a set of constraints that ensure the geometry provides the desired behavior. The construction of the BEP-Model from the sketch and behavior description is the primary task and source of difficulty in this undertaking. SketchIT begins by abstracting the sketch to produce a qualitative configuration space (qc-space) which it then uses as its primary representation of behavior. SketchIT modifies this initial qc-space until qualitative simulation verifies that it produces the desired behavior. SketchIT's task is then to find geometries that implement this qc-space. It does this using a library of qc-space fragments. Each fragment is a piece of parametric geometry with a set of constraints that ensure the geometry implements a specific kind of boundary (qcs-curve) in qc-space. SketchIT assembles the fragments to produce the BEP-Model. SketchIT produces design variants by mapping the qc-space to multiple implementations, and by transforming rotating parts to translating parts and vice versa.

The Design of a Mechanical Assembly System

This thesis describes a mechanical assembly system called LAMA (Language for Automatic Mechanical Assembly). The goal of the work was to create a mechanical assembly system that transforms a high-level description of an automatic assembly operation into a program or execution by a computer controlled manipulator. This system allows the initial description of the assembly to be in terms of the desired effects on the parts being assembled. Languages such as WAVE [Bolles & Paul] and MINI [Silver] fail to meet this goal by requiring the assembly operation to be described in terms of manipulator motions. This research concentrates on the spatial complexity of mechanical assembly operations. The assembly problem is seen as the problem of achieving a certain set of geometrical constraints between basic objects while avoiding unwanted collisions. The thesis explores how these two facets, desired constraints and unwanted collisions, affect the primitive operations of the domain.

Mechanical defenses in leaves eaten by Costa Rican howling monkeys (Alouatta palliata).

Primate species often eat foods of different physical properties. This may have implications for tooth structure and wear in those species. The purpose of this study was to examine the mechanical defenses of leaves eaten by Alouatta palliata from different social groups at Hacienda La Pacifica in Costa Rica. Leaves were sampled from the home-ranges of groups living in different microhabitats. Specimens were collected during the wet and dry seasons from the same tree, same plant part, and same degree of development as those eaten by the monkeys. The toughness of over 300 leaves was estimated using a scissors test on a Darvell mechanical tester. Toughness values were compared between social groups, seasons, and locations on the leaves using ANOVA. Representative samples of leaves were also sun-dried for subsequent scanning electron microscopy and energy dispersive x-ray (EDX) analyses in an attempt to locate silica on the leaves. Both forms of mechanical defense (toughness and silica) were found to be at work in the plants at La Pacifica. Fracture toughness varied significantly by location within single leaves, indicating that measures of fracture toughness must be standardized by location on food items. Monkeys made some food choices based on fracture toughness by avoiding the toughest parts of leaves and consuming the least tough portions. Intergroup and seasonal differences in the toughness of foods suggest that subtle differences in resource availability can have a significant impact on diet and feeding in Alouatta palliata. Intergroup differences in the incidence of silica on leaves raise the possibility of matching differences in the rates and patterns of tooth wear.