• 한국기계가공학회지
• /
• 제19권5호
• /
• pp.45-52
• /
• 2020

Recently, design for additive manufacturing (DfAM) technology has become a prominent design methodology for exploiting 3D printing, which leads the Fourth Industrial Revolution. When manufactured by the 3D printing method, it is possible to produce several shapes compared to the conventional casting or cutting process. DfAM-as a newly-proposed design methodology-can be used to specially design products with various shapes to apply functional requirements. Topology optimization verifies load paths to determine the draft design, and a shape-optimized design with objective functions for weight reduction enables efficient lightweight product design. In this study, by using these two DfAM technologies, a lightweight and optimal design is constructed for a node part of a vehicle body with a space frame designed for a lightweight vehicle. DfAM methodologies for concept design and detailed design, and the associated results, are presented. Finally, the product was additively manufactured, a fatigue performance test was performed, and the design reliability was verified.

• 한국분말재료학회지
• /
• 제27권5호
• /
• pp.388-393
• /
• 2020

The enamel powders used traditionally in Korea are produced by a ball-milling process. Because of their irregular shapes, enamel powders exhibit poor flowability. Therefore, polygonal enamel powders are only used for handmade cloisonné crafts. In order to industrialize or automate the process of cloisonné crafts, it is essential to control the size and shape of the powder. In this study, the flowability of the enamel powders was improved using the spheroidization process, which employs the RF plasma treatment. In addition, a simple grid structure and logo were successfully produced using the additive manufacturing process (powder bed fusion), which utilizes spherical enamel powders. The additive manufacturing technology of spherical enamel powders is expected to be widely used in the field of cloisonné crafting in the future.

• Tribology and Lubricants
• /
• 제37권1호
• /
• pp.1-6
• /
• 2021

This paper presents the experimental results of hydrophobic surfaces developed using a stereolithography-based additive-manufacturing technique. The additive manufacturing technique can be used to manufacture objects with complex geometries from computer-aided design data. Several additive manufacturing methods, such as selective laser sintering, fused deposition modeling, stereolithography apparatus (SLA), and inkjet-based system, have been developed. The SLA is a form of three-dimensional printing technology used to create prototypes, patterns, and production parts in successive layers through photochemical processes. Light causes chemical monomers and oligomers to cross-link together to form objects composed of polymers. Moreover, this method is economical for fabricating surfaces with high output resolution and quality. Here, we fabricate various surfaces using different shapes using an SLA. The surfaces with micro-patterns are fabricated for 10 cases, including the biomimetic surface. The fabricated surfaces with various micro-patterns are evaluated for hydrophobicity performance based on the static contact angle. The contact angle is measured three times for each case, and the averaged value is used. The results indicate that the arrangements in a staggered structure have a larger contact angle than those in a line when the same micro-pattern is applied. Moreover, the mimetic surfaces exhibit more hydrophobic characteristics than those of artificial micro-patterns.

• Current Optics and Photonics
• /
• 제6권4호
• /
• pp.381-391
• /
• 2022

Two-photon-polymerization additive-manufacturing systems feature high resolution and precision. However, there are few reports on specific methods and possible problems concerning the use of small lasers to independently build such platforms. In this paper, a femtosecond-laser two-photon-polymerization additive-manufacturing system containing an optical unit, control unit, monitoring unit, and testing unit is built using a miniature femtosecond laser, with a detailed building process and corresponding control software that is developed independently. This system has integrated functions of light-spot detection, interface searching, micro-/nanomanufacturing, and performance testing. In addition, possible problems in the processes of platform establishment, resin preparation, and actual polymerization for two-photon-polymerization additive manufacturing are explained specifically, and the causes of these problems analyzed. Moreover, the impacts of different power levels and scanning speeds on the degree of polymerization are compared, and the influence of the magnification of the object lens on the linewidth is analyzed in detail. A qualitative analysis model is established, and the concepts of the threshold broadening and focus narrowing effects are proposed, with their influences and cooperative relation discussed. Besides, a linear structure with micrometer accuracy is manufactured at the millimeter scale.

• 소성∙가공
• /
• 제33권1호
• /
• pp.36-42
• /
• 2024

Additive manufacturing with 3XX austenitic stainless steels has been widely investigated during a decade due to its high strength, good corrosion resistance, and fair weldability. However, in recently, Ni price drastically increased due to the high demand of secondary battery for electric mobilities. Thus, it is essential to substitute the Ni with Mn for reducing stainless steels price. Meanwhile, the chemical composition changes in stainless steels not only affect to its properties but also change the optimal processing parameters during additive manufacturing. Therefore, it is necessary to optimize the processing parameters of each alloy for obtaining high-quality product using additive manufacturing. After processing optimization, mechanical properties and microstructure of the laser-powder bed fusion processed Fe-15Cr-7Ni-3Mn alloy were investigated in both room (298 K) and cryogenic (77 K) temperatures. Since the temperature reduction affects to the deformation mechanism transition, multi-scale microstructural characterization technique was conducted to reveal the deformation mechanism of each sample.

• Corrosion Science and Technology
• /
• 제18권6호
• /
• pp.258-266
• /
• 2019

The objective of this study was to evaluate corrosion resistance of additive manufactured 316L stainless steel and alloy 625 powders widely used in corrosion resistance alloys of marine industry in comparison with cast alloys. Directed Energy Deposition (DED) method was used in this work for sample production. DED parameter adjustment was also studied for optimum manufacturing and for minimizing the influence of defects on corrosion property. Additive manufactured alloys showed lower corrosion resistance in seawater compared to cast alloys. The reason for the degradation of anti-corrosion property was speculated to be due to loss of microstructural integrity intrinsic to the additive manufacturing process. Application of heat treatment with various conditions after DED was attempted. The effect of heat treatments was analyzed with a microstructure study. It was found that 316L and alloy 625 produced by the DED process could recover their expected corrosion resistance when heat treated at 1200 ℃.

• 한국기계가공학회지
• /
• 제14권3호
• /
• pp.9-14
• /
• 2015

The Direct Metal Tooling (DMT) process is a kind of additive manufacturing processes, which is developed using various commercial steel powders, such as P20, P21, SUS420, and other non-ferrous metal powders. The DMT process is a versatile process that can be applied to various fields, such as the molding industry, the medical industry, and the defense industry. Among them, the application of the DMT process to the molding industry is one of its most attractive and practical applications, since the conformal cooling channel cores of injection molds can be fabricated at a slightly expensive cost by using the hybrid fabrication method of DMT technology compared with parts fabricated with machining technology. The main objectives of this study are to provide various characteristics of the parts made using the DMT process compared with the same parts machined from bulk materials and evaluate the performance of the injection mold equipped with a conformal cooling channel core fabricated using the hybrid method of the DMT process.

• Structural Engineering and Mechanics
• /
• 제86권1호
• /
• pp.93-107
• /
• 2023

In this paper, a density based topology optimization is proposed for generating of supports required in additive manufacturing to maintain the overhanging regions of main structures during layer by layer fabrication process. For this purpose, isogeometric analysis method is employed to model geometry and structural analysis of main and support structures. In order to model the problem two cases are investigated. In the first case, design domain of supports can easily be separated from the main structure by using distinct isogeometric patches. The second case happens when the main structure itself is optimized by using topology optimization and the supports should be designed in the voids of optimum layout. In this case, in order to avoid boundary identification and re-meshing process for separating design domain of supports from main structure, a parameterization technique is proposed to identify the design domain of supports. To achieve this, two density functions are defined over the entire domain to describe the main structure and supporting areas. On the other hand, since supports are under gravity loads while main structure and its stiffness is not completed during manufacturing process, in the proposed method, stiffness of the main structure is considered to be trivial and the gravity loads are also naturally applied to design support structures. By doing so, the results show reasonable supports are created to protect, continuously, overhanging surfaces of the main structure. Several examples are presented to demonstrate the efficiency of the proposed method and compare the results with literature.

• 한국압력기기공학회 논문집
• /
• 제19권1호
• /
• pp.11-19
• /
• 2023

Additive manufacturing technology, called as 3D printing, is one of fourth industrial revolution technologies that can drive innovation in the manufacturing process, and thus should be applied to nuclear industry for various purposes according to the manufacturing trend change in the future. In this paper, we performed tensile tests of 3D printed stainless steel 316L as-built specimens manufactured by two types of technology; DED (Directed Energy Deposition) and PBF (Powder Bed Fusion). Their mechanical properties (tensile strength, yield strength, elongation and reduction of area) were compared. As a result of comparison, the mechanical properties of the PBF specimens were slightly better than those of DED specimens. In the same additive type of specimens, the tensile and yield strength of specimens in the X and Y direction were higher than those in the Z direction, but the elongation and ROA were lower.

• 한국분말재료학회지
• /
• 제27권4호
• /
• pp.318-324
• /
• 2020

In the present work, an explicit finite element analysis technique is introduced to analyze the thermal stress fields present in the additive manufacturing process. To this purpose, a finite element matrix formulation is derived from the equations of motion and continuity. The developed code, NET3D, is then applied to various sample problems including thermal stress development. The application of heat to an inclusion from an external source establishes an initial temperature from which heat flows to the surrounding body in the sample problems. The development of thermal stress due to the mismatch between the thermal strains is analyzed. As mass scaling can be used to shorten the computation time of explicit analysis, a mass scaling of 108 is employed here, which yields almost identical results to the quasi-static results.