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Parameter optimization of automated fiber placement based on CCD response surface method

JOURNAL OF REINFORCED PLASTICS AND COMPOSITES 2024年

作者： Lu, Tianyao Li, Junli Zhang, Yilian Liu, Gang Qian, Bo Zhang, Liqiang Mao, Jian Shanghai Univ Engn Sci Sch Automot & Mech Engn 333 Longteng Rd Shanghai 201620 Peoples R China Shanghai Univ Sch Electromech Engn & Automat Shanghai Peoples R China Zhiyuan Adv Mfg Technol Res Ctr Chengdu Peoples R China Key Lab Intelligent Mfg Technol Complex Large Scal Shanghai Peoples R China

Defects in the automatic fiber placement (AFP) directly affect the prepreg bonding strength, resulting in a less strong product than expected. Improper process parameter selection is one of the major factors contributing to layup defects. However, there is a significant degree of uncertainty associated with the parameters that affect the lay-up quality and currently few studies that use response surfaces to consider the interaction of these parameters. In general, it is necessary to obtain a more accurate combination of process parameters through experiment, which is time-consuming and consumable. Moreover, it is difficult to investigate the interrelation between process parameters. Therefore, this paper presents a method of placement parameter optimization based on lap shear strength (LSS) to achieve high-quality and high-strength AFP process control. Firstly, this article establishes a comprehensive quality evaluation system by analyzing the causes of defects in AFP process. Secondly, the central composite design of experiments (CCD) response surface methodology was used to effectively optimize the process parameters and to understand the interactions between the various factors. A prediction model with quadratic polynomial regression equations for four process parameters and laydown quality was developed. Based on the regression equations, the process parameters with optimal lay-up quality were obtained. Then, using 30 sets of process parameters from the response surface experiment, lap samples were made for tensile testing. The lap shear strength of tows under various process conditions was studied, and the experimental results were consistent with the response surface analysis results. Finally, by analyzing the quality evaluation curve and load-time curve, it was found that the trend of AFP quality evaluation score and LSS was practically the same. Data analysis shows that placement using optimized parameters corresponding to higher scoring samples has higher l

关键词： Automated fiber placement central composite design response surface method layup quality process parameters optimization

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Experimental investigation on the effect of the Fused Deposition Modeling parameters on the processing of Polyether Ether Ketone

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Journal of Materials Research and Technology 2025年 36卷 8007-8021页

作者： Erica Billè Marina Franulović Alessandro Gambitta David Liović Alfredo Rondinella Federico Scalzo Marco Sortino Giovanni Totis Emanuele Vaglio Polytechnic Department of Engineering and Architecture University of Udine Via delle Scienze 206 Udine 33100 Italy University of Rijeka Faculty of Engineering Vukovarska 58 Rijeka 51000 Croatia Elettra-Sincrotrone Trieste Area Science Park Basovizza Trieste 34149 Italy

The use of Fused Deposition Modeling to produce high-performance polyether ether ketone is steadily increasing. However, the limited availability of in-depth studies on the process hampers its potential for industrial and scientific applications. This study investigates how nozzle temperature, nozzle speed, and layer thickness influence crucial product properties, including surface roughness, dimensional accuracy, and mechanical behavior, by means of Confocal and Scanning Electron Microscopy, X-ray Micro-Computed Tomography, Fourier-Transform Infrared Spectroscopy, Energy-Dispersive X-ray Spectroscopy, tensile and hardness tests. Selected samples were further analyzed in exceptional detail by synchrotron radiation, while degassing behavior in Ultra-High Vacuum conditions was explored for optimal configurations. The results highlight the critical influence of process parameters on the final properties of FDM-printed PEEK parts. Nozzle temperature proved to be the most significant factor in improving both mechanical performance and surface finish, while nozzle speed predominantly affected dimensional accuracy. Layer thickness had a secondary effect, mainly influencing surface roughness and contributing to internal defects and variability in mechanical properties. The combination of parameters that yielded the most balanced performance was identified as a nozzle temperature of 420 °C, nozzle speed of 40 mm/s, and layer thickness of 0.1 mm. Across all tested configurations, the maximum Ultimate Tensile Strength achieved was 84 MPa, while the highest recorded part density reached 99.8%. These outcomes enabled the successful manufacturing of components suitable for ultra-high vacuum environments. The process was validated through the fabrication of a benchmark part with complex geometries, demonstrating the capability of FDM to produce high-precision, high-performance components.

关键词： Additive manufacturing Fused deposition modeling PEEK process parameters optimization

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Morphology analysis and process optimization of μ-SLA 3D manufactured micro-nano conic structure

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Journal of Intelligent Manufacturing and Special Equipment 2024年第1期5卷 203-220页

作者： Chongjun Wu Yutian Chen Xinyi Wei Junhao Xu Dongliu Li College of Mechanical Engineering Donghua University Shanghai China Saic Volkswagen Automobile Co. LTD Shanghai China Donghua University Shanghai China Sicher Elevator Co. Ltd. Huzhou China

Purpose This paper is devoted to prepare micro-cone structure with variable cross-section size by Stereo Lithography Appearance (SLA)-based 3D additive manufacturing technology. It is mainly focused on analyzing the forming mechanism of equipment and factors affecting the forming quality and accuracy, investigating the influence of forming process parameters on the printing quality and optimization of the printing quality. This study is expected to provide a µ-SLA surface preparation technology and process parameters selection with low cost, high precision and short preparation period for microstructure forming. Design/methodology/approach The µ-SLA process is optimized based on the variable cross-section micro-cone structure printing. Multi-index analysis method was used to analyze the influence of process parameters. The process parameter influencing order is determined and validated with flawless micro array structure. Findings After the optimization analysis of the top diameter size, the bottom diameter size and the overall height, the influence order of the printing process parameters on the quality of the micro-cone forming is: exposure time (B), print layer thickness (A) and number of vibrations (C). The optimal scheme is A1B3C1, that is, the layer thickness of 5 µm, the exposure time of 3000 ms and the vibration of 64x. At this time, the cone structure with the bottom diameter of 50 µm and the cone angle of 5° could obtain a better surface structure. Originality/value This study is expected to provide a µ-SLA surface preparation technology and process parameters selection with low cost, high precision and short preparation period for microstructure forming.

关键词： Micro-cone Micro-nano additive manufacturing Orthogonal experimental design process parameters optimization

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Numerical prediction of microstructure evolution of high-speed railway axle formed using hot cross wedge rolling

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MATERIALS TODAY COMMUNICATIONS 2023年 35卷

作者： Huo, Yuanming Huo, Cunlong Ren, Xu He, Tao Hosseini, Seyed Reza Elmi Wang, Baoyu Cui, Yongliang Jia, Changyuan Liu, Keran Du, Xiangyang Shanghai Univ Engn Sci Sch Mech & Automot Engn Shanghai 201620 Peoples R China Iran Univ Sci & Technol IUST Sch Met & Mat Engn Tehran Iran Univ Sci & Technol Beijing Sch Mech Engn Beijing 100083 Peoples R China Taiyuan Heavy Ind Railway Transit Equipment Co Ltd Taiyuan 030032 Peoples R China

The ununiform distribution of the grain size and coarse crystals is easy to be appeared in the high-speed railway axle (HSRA) formed by hot cross wedge rolling (CWR). It seriously reduces the comprehensive mechanical properties of the HSRA. It is vital to numerically predict microstructure evolution, so that the mixed and coarse crystals can be accurately controlled via process parameters optimization. In this study, the microstructure evolution model of the 40CrNiMo steel was developed and implemented into the DEFORM-3D software by programming a user subroutine to simulate hot upsetting. Microstructure of specimens after hot upsetting experiment was investigated to validate the finite element (FE) prediction model of microstructure evolution. The simulation results were close to the experimental results, which verifies that the established microstructure evolution model has a good predictability. The developed microstructure evolution model and the FE prediction system of hot CWR were used to simulate the forming of HSRA. Hot CWR simulations of HSRA was conducted at rolling temperature of 1000 degrees C and rolling sped of 1.5 r/min with initial grain size of 200um. Numerical prediction of dynamic recrystallization (DRX) volume fraction and average grain size in three segments of CWR, such as wedge entering segment, widening segment and finishing segment, were carried out to study the microstructure evolution of CWR. Results show that the maximum average grain size locates in the heart of hub axle section, which is smaller than grade 5 and above (d & LE;62.5 & mu;m). It indicates that the microstructure of HSRA after CWR meet the requirements of grain structure grade in international standard of EN13261. Effects of rolling temperatures, rolling speeds and initial grain sizes on the microstructure distribution after hot CWR were analyzed using FE simulations for 40CrNiMo steel. The rolling temperature of 1050 degrees C, rolling speed of 6 r/min and initial average g

关键词： High-speed railway axle Cross wedge rolling Dynamic recrystallization Numerical simulation process parameters optimization

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process Parameter optimization for Hybrid Manufacturing of PLA Components with Improved Surface Quality

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POLYMERS 2023年第17期15卷 3610-3610页

作者： Pascu, Sergiu Balc, Nicolae Tech Univ Cluj Napoca Fac Ind Engn Robot & Prod Management Dept Mfg Engn Memorandumului 28 Cluj Napoca 400114 Romania

This paper presents a new method of process parameter optimization, adequate for 3D printing of PLA (Polylactic Acid) components. The authors developed a new piece of Hybrid Manufacturing Equipment (HME), suitable for producing complex parts made from a biodegradable thermoplastic polymer, to promote environmental sustainability. Our new HME equipment produces PLA parts by both additive and subtractive techniques, with the aim of obtaining accurate PLA components with good surface quality. A design of experiments has been applied for optimization purposes. The following manufacturing parameters were analyzed: rotation of the spindle, cutting depth, feed rate, layer thickness, nozzle speed, and surface roughness. Linear regression models and neural network models were developed to improve and predict the surface roughness of the manufactured parts. A new test part was designed and manufactured from PLA to validate the new mathematical models, which can now be applied for producing complex parts made from polymer materials. The neural network modeling (NNM) allowed us to obtain much better precision in predicting the final surface roughness (Ra), as compared to the conventional linear regression models (LNM). Based on these modelling methods, the authors developed a practical methodology to optimize the process parameters in order to improve the surface quality of the 3D-printed components and to predict the actual roughness values. The main advantages of the results proposed for hybrid manufacturing using polymer materials like PLA are the optimized process parameters for both 3D printing and milling. A case study has been undertaken by the authors, who designed a specific test part for their new hybrid manufacturing equipment (HME), in order to test the new methodology of optimizing the process parameters, to validate the capability of the new HME. At the same time, this new methodology could be replicated by other researchers and is useful as a guideline on how to

关键词： hybrid manufacturing biodegradable thermoplastic polymer PLA components process parameters optimization roughness prediction neural network modeling

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The Influence of Thermoplastic Composite Recycling on the Additive Manufacturing process and In-Use Phase as Candidate Materials for Wearable Devices Applications

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POLYMERS 2023年第18期15卷 3775-3775页

作者： Papatheodorou, Alexandra Gavalas, Iakovos Ntenekou, Despoina Karatza, Anna BioG3D PC 1 Lavriou AveTechnol & Cultural Pk Lavr Lavrion 19500 Greece

Fused filament fabrication (FFF) is a popular additive manufacturing (AM) method for creating thermoplastic parts with intricate geometrical designs. Pure thermoplastic materials utilized in FFF, whose polymeric matrix is reinforced with other materials, such as carbon fibers (CFs), introduce products with advanced mechanical properties. However, since not all of these materials are biodegradable, the need for recycling and reuse immediately emerges to address the significant problem of how to dispose of their waste. The proposed study evaluates the printability, surface morphology and in vitro toxicity of two thermoplastic-based composite materials commonly used in wearable device manufacturing to provide enhanced properties and functionalities, making them suitable for various applications in the field of wearable devices. Tritan Copolyester TX1501 with 7.3% chopped CFs (cCFs) and Polyamide 12 (PA12) with 8.6%cCFs and 7.5% iron Magnetic Nanoparticles (MNPs)-Fe4O3 were used in the discrete ascending cycles of recycling, focusing on the surface quality performance optimization of the printed parts. Through stereoscopy evaluation, under-extrusion, and over-extrusion defects, as well as non-uniform material flow, are assessed in order to first investigate the influence of various process parameters' application on the printing quality of each material and, second, to analyze the optimal value fluctuation of the printing parameters throughout the recycling cycles of the materials. The results indicate that after applying certain adjustments to the main printing parameter values, the examined recycled reinforced materials are still effectively 3D printed even after multiple cycles of recycling. A morphology examination using scanning electron microscope (SEM) revealed surface alterations, while a cytotoxicity assessment revealed the adverse effects of both materials in the form of cell viability and the release of proinflammatory cytokines in the cell culture medium.

关键词： printability evaluation process parameters optimization composite materials recycled 3D-printing filaments cytotoxicity

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optimization of process parameters of SMAW process using NN-FGRA from the sustainability view point

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JOURNAL OF INTELLIGENT MANUFACTURING 2017年第6期28卷 1459-1480页

作者： Vimal, K. E. K. Vinodh, S. Raja, A. Natl Inst Technol Dept Prod Engn Tiruchirappalli 620015 Tamil Nadu India Bharat Heavy Elect Ltd Welding Res Inst Tiruchirappalli Tamil Nadu India

Welding process does not possess a good environmental image due to fumes, noise and other health hazards. But, it has been widely applied and is irreplaceable as far as structural industries are concerned. In welding process, many factors are responsible for environmental burdens, of which this study investigates and optimizes process parameters. Based on the pilot study, operating levels for parameters like current, voltage and welding speed, and various responses were identified. Further, the responses considered in the study include spatter, slag, fume generation rate, particulates and power consumption. A full factorial design of three factors at five levels requires 125 experiments for a complete analysis;however the conduct of a full factorial design experiment is expensive and consumes much time. Hence, orthogonal design was adopted for three inputs and five levels and 27 experiments were conducted. Further, five back propagation neural network model with network structure of 3-12-1 was individually developed to predict responses. values obtained for back propagation neural network model pertaining to slag, spatter, power consumption, fume generation rate and particulate formation are 0.99, 0.99, 0.989, 0.965 and 0.97 respectively. The responses for full factorial interaction were simulated. Fuzzy based grey relational analysis was used to optimize process parameters. Finally, life cycle assessment methodology outlined by ISO 14040 and 14044 was adopted to quantify the improvement in environmental performance due to parameter optimization. Thus, the proposed methodology helps to improve environmental performance of the manufacturing process with the experiments conducted using partial factorial design. Apart from environmental benefits, economic benefits and man hours saving are attained without compromising accuracy.

关键词： Sustainability practices process parameters optimization Neural network Grey fuzzy methods Life cycle assessment

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A study of welding process in connecting borosilicate glass by picosecond laser pulses based on response surface methodology

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OPTICS AND LASER TECHNOLOGY 2020年 131卷 106427-106427页

作者： Huang, Shu Chen, Rui Zhang, Hang Ye, Jiamei Yang, Xiaole Sheng, Jie Jiangsu Univ Sch Mech Engn Zhenjiang 212013 Jiangsu Peoples R China

Picosecond laser welding process was investigated on connecting borosilicate glass. A three-factor with five-level central composite rotatable design was utilized in the experimental study. The response surface methodology (RSM) was used to optimize the key process parameters which determined the weld quality, which includes laser power, welding speed and repetition frequency. The micro-hardness, surface microscopic morphologies and weld width were also characterized respectively. Energy dispersive spectrometer (EDS) line scans were performed to analyze the diffusion and migration of network formers elements during the laser welding process. The lap-shear strength of welded joints was determined by an electronic universal testing machine. The results indicated that the weld seam was continuous and uniform by using optimized process parameters with the lapshear strength ranging from 3.25 to 6.92 MPa and the weld width ranging from 250.9 to 430.8 mu m. The diffusion of Si and O elements occurred during the laser welding process, which was also one of the reasons for the improvement of the micro-hardness of the welded zone. The established mathematical model can precisely reflect the interactive influence of the picosecond laser welding process parameters on the lap-shear strength and weld width. Furthermore, the optimized prediction results were consistent with test results.

关键词： Picosecond laser Borosilicate glass Response surface methodology process parameters optimization Weld quality

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Co-liquefaction of Tuncbilek lignite with algae (spirulina species): Effect of process parameters and characterization of chars and oils

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RESULTS IN ENGINEERING 2022年 16卷

作者： Cavusoglu, Bugra Koyunoglu, Cemil Karaca, Huseyin Inonu Univ Engn Fac Chem Engn Dept Elazig Rd 15th Km TR-44280 Malatya Turkey Yalova Univ Engn Fac Energy Syst Engn Dept Cinarcik Rd 5th Km TR-77200 Yalova Turkey

Nowadays, to reduce the cost of coal liquefaction and to produce a new liquid fuel alternative to petroleum, it is considered a more convenient method to liquefy coal and biomass together instead of solely coal liquefaction. Liquefaction experiments were carried out by changing the solvent/solid ratio of 1/1-5/1, reaction temperature 320-400 degrees C, reaction time 30-90 min, and algae/lignite ratio in the range of 1/1-5/1. As a result of this study, the most suitable process parameters obtained by considering total conversion are;solvent/solid ratio 3/1, reaction time 60 min, algae/lignite ratio 4/1, and reaction temperature 380 degrees C. Under these conditions, the highest total conversion is approximately 80% and 77% in catalytic and non-catalytic conditions, respectively. Under non-catalytic conditions of co-liquefaction experiments due to the GC-MS results, cyclopentane (raw material of motor oil), pentadecane, 2-methyl-naphthalene, octa-ethylene glycol, ethylene oxide heptamer are the main products of optimum parameters aforementioned for oil. They are mainly used in fuel technology and used in the chemical industry as raw materials mean low-cost production as well.

关键词： Tuncbilek lignite Algae process parameters optimization Co-processing Products characterization Oil+gas yields

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Grinding process parameters optimization and surface performance analysis of spiral bevel gear based on the orthogonal test

Grinding process parameters optimization and surface perform...

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3rd International Conference on Manufacturing Science and Engineering (ICMSE 2012)

作者： Ming, Xingzu Yan, Hongzhi He, Guoqi Kong, Xianghan Hunnan Ind Univ Zhuzhou City Hunan Peoples R China Cent S Univ Changsha city Hunan Peoples R China

ISBN: (纸本)9783037853726

Based on the experimental conditions of generation grinding of spiral bevel gear, the grinding orthogonal test design of L-16(4(5)) is made, and the results of grinding orthogonal test are obtained. On this basis, the range and variance analyses are carried out by using an integrated balance method, and the optimizing configuration of grinding process parameters of spiral bevel gear is obtained. The test regression models of three grinding evaluating indicators of spiral bevel gear, such as the grinding surface roughness R-a, metamorphic layer depth h and removal rate Z(w), are set up by using a method of multivariate nonlinear least square. The maximal absolute value of relative error between computing values and testing ones is 18.41 percent by test validation, and this shows that the regression models are more effective. Through the test optimization of grinding surface performance, the value of grinding surface roughness R-a is more less 0.1 mu m than one of the normal grinding process, and other comprehensive performances are better. The pre-control measures of grinding process optimization of spiral bevel gear are also put forward. These provide a basis for the improvement of grinding surface quality of spiral bevel gear.

关键词： Grinding Spiral bevel gear Orthogonal test process parameters optimization Surface performance

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