TY - JOUR
T1 - In-Process Thread Orientation Monitoring in Additive Manufacturing
AU - Xu, Xiaochi
AU - Vallabh, Chaitanya Krishna Prasad
AU - Krishnan, Ajay
AU - Volk, Scott
AU - Cetinkaya, Cetin
N1 - Publisher Copyright:
© 2019, Mary Ann Liebert, Inc.
PY - 2019/3
Y1 - 2019/3
N2 - Additive manufacturing/3D printing (AM/3DP) has become a practical manufacturing modality in fabricating highly-complex/optimized parts, providing a form-free flexibility for the development of high-value/high-performance products. However, significant build-to-build variabilities in geometric tolerances and mechanical strength have often been reported as shortcomings. Currently, AM/3DP lacks a practical in situ/real-time quality monitoring utility. In fused filament fabrication, the quality of production in a uniform build depends on two fundamental parameters: the strength of each thread (an extruded line of filament material, created by the heated nozzle) and the nature/strength of thread-to-thread bonds in (in-plate) horizontal and (out-of-plane) vertical directions. In this study, we present an in situ/real-time monitoring approach, in which, instead of monitoring the actual build, the spectral characteristics of elastic wave propagation in a specially designed artifact having periodic internal structures are monitored. The design of an artifact is based on the geometric complexities of the actual build, and its internal structures amplify certain specified aspects of its AM/3DP process and materials. Furthermore, the artifact is substantially simpler and smaller than the actual build it represents, thus considerably easier to monitor. In this study, the artifact design consists of repeating biperiodic substructures of sparsely located threads. As a model problem, in this study we introduce and report a simple phononic crystal artifact design with varying thread-crossing angles and the effects of thread orientation and placement on the shifts of its pass and stop bands and/or the creation of stop bands. In current proof-of-concept study, an experimental setup and basic artifact designs are described, off-line monitoring data are presented, and the sensitivity of the approach is analyzed.
AB - Additive manufacturing/3D printing (AM/3DP) has become a practical manufacturing modality in fabricating highly-complex/optimized parts, providing a form-free flexibility for the development of high-value/high-performance products. However, significant build-to-build variabilities in geometric tolerances and mechanical strength have often been reported as shortcomings. Currently, AM/3DP lacks a practical in situ/real-time quality monitoring utility. In fused filament fabrication, the quality of production in a uniform build depends on two fundamental parameters: the strength of each thread (an extruded line of filament material, created by the heated nozzle) and the nature/strength of thread-to-thread bonds in (in-plate) horizontal and (out-of-plane) vertical directions. In this study, we present an in situ/real-time monitoring approach, in which, instead of monitoring the actual build, the spectral characteristics of elastic wave propagation in a specially designed artifact having periodic internal structures are monitored. The design of an artifact is based on the geometric complexities of the actual build, and its internal structures amplify certain specified aspects of its AM/3DP process and materials. Furthermore, the artifact is substantially simpler and smaller than the actual build it represents, thus considerably easier to monitor. In this study, the artifact design consists of repeating biperiodic substructures of sparsely located threads. As a model problem, in this study we introduce and report a simple phononic crystal artifact design with varying thread-crossing angles and the effects of thread orientation and placement on the shifts of its pass and stop bands and/or the creation of stop bands. In current proof-of-concept study, an experimental setup and basic artifact designs are described, off-line monitoring data are presented, and the sensitivity of the approach is analyzed.
KW - defect detection
KW - manufacturing quality
KW - phononic crystal artifacts
KW - real-time in situ process monitoring
KW - thread orientation
KW - wave propagation in periodic structures
UR - http://www.scopus.com/inward/record.url?scp=85062029467&partnerID=8YFLogxK
UR - http://www.scopus.com/inward/citedby.url?scp=85062029467&partnerID=8YFLogxK
U2 - 10.1089/3dp.2018.0135
DO - 10.1089/3dp.2018.0135
M3 - Article
AN - SCOPUS:85062029467
SN - 2329-7662
VL - 6
SP - 21
EP - 30
JO - 3D Printing and Additive Manufacturing
JF - 3D Printing and Additive Manufacturing
IS - 1
ER -