Hostname: page-component-848d4c4894-pjpqr Total loading time: 0 Render date: 2024-06-14T18:59:16.441Z Has data issue: false hasContentIssue false
  • English
  • Français

Stress concentrations and design for additive manufacturing: a design artefact approach to investigation

Published online by Cambridge University Press:  16 May 2024

Didunoluwa Obilanade ,
Owen Rahmat Peckham ,
Adam McClenaghan ,
James Gopsill  and
Peter Törlind
Didunoluwa Obilanade*
Affiliation:
Luleå University of Technology, Sweden
Owen Rahmat Peckham
Affiliation:
University of Bristol, United Kingdom
Adam McClenaghan
Affiliation:
University of Bristol, United Kingdom
James Gopsill
Affiliation:
University of Bristol, United Kingdom
Peter Törlind
Affiliation:
Luleå University of Technology, Sweden
*
Didunoluwa.Obilanade@ltu.se

Abstract

Core share and HTML view are not available for this content. However, as you have access to this content, a full PDF is available via the ‘Save PDF’ action button.

The accelerated rate of product development and design complexities offered by Additive Manufacturing (AM) has allowed for innovation in the space industry. However, the surface roughness of parts poses a challenge, as it impacts performance and is tied to design choices. Design tools for traditional manufacturing methods fall short in AM contexts, prompting the need for alternative design processes. This work proposes an experimental approach to design for AM investigation using design artefacts to explore a process-structure-property-performance relationship.

Keywords

additive manufacturingdesign artefactdesign for additive manufacturingsurface roughnessprototyping
Type
Design for Additive Manufacturing
Information
Proceedings of the Design Society , Volume 4: DESIGN 2024 , May 2024 , pp. 1789 - 1798
Creative Commons
Creative Common License - CCCreative Common License - BYCreative Common License - NCCreative Common License - ND
This is an Open Access article, distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives licence (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is unaltered and is properly cited. The written permission of Cambridge University Press must be obtained for commercial re-use or in order to create a derivative work.
Copyright
The Author(s), 2024.

References

ASTM. (2002), “Standard Practice for Conducting Force Controlled Constant Amplitude Axial Fatigue Tests of Metallic Materials”, Test, Vol. 03, pp. 4–8, https://dx.doi.org/10.1520/E0466-21.2.Google Scholar
Axsom, T. (2022), “Stress Concentrations: How to Identify and Reduce Them in Your Designs | Fictiv”, Fictiv, 3 July, available at: https://www.fictiv.com/articles/stress-concentrations-how-to-identify-and-reduce-them-in-your-designs (accessed 21 November 2023).Google Scholar
Benedetti, M., Cazzolli, M., Fontanari, V. and Leoni, M. (2016), “Fatigue limit of Ti6Al4V alloy produced by Selective Laser Sintering”, Procedia Structural Integrity, Elsevier B.V., Vol. 2, pp. 3158–3167, https://dx.doi.org/10.1016/j.prostr.2016.06.394.Google Scholar
Benedetti, M., du Plessis, A., Ritchie, R.O., Dallago, M., Razavi, N. and Berto, F. (2021), “Architected cellular materials: A review on their mechanical properties towards fatigue-tolerant design and fabrication”, Materials Science and Engineering: R: Reports, Elsevier, Vol. 144, p. 100606, https://dx.doi.org/10.1016/J.MSER.2021.100606.CrossRefGoogle Scholar
Ding, D., Pan, Z., Cuiuri, D. and Li, H. (2015), “Wire-feed additive manufacturing of metal components: technologies, developments and future interests”, International Journal of Advanced Manufacturing Technology, Vol. 81 No. 1–4, pp. 465–481, https://dx.doi.org/10.1007/s00170-015-7077-3.CrossRefGoogle Scholar
Dordlofva, C. and Törlind, P. (2020), “Evaluating design uncertainties in additive manufacturing using design artefacts: examples from space industry”, Design Science, Cambridge University Press, Vol. 6, p. e12, https://dx.doi.org/10.1017/dsj.2020.11.Google Scholar
Gibson, I., Rosen, D., Stucker, B. and Khorasani, M. (2020), Additive Manufacturing Technologies, Additive Manufacturing Technologies, https://dx.doi.org/10.1007/978-3-030-56127-7.CrossRefGoogle Scholar
Gradl, P., Cervone, A. and Colonna, P. (2023), “Influence of build angles on thin-wall geometry and surface texture in laser powder directed energy deposition”, Materials and Design, Elsevier Ltd, Vol. 234 No. September, p. 112352, https://dx.doi.org/10.1016/j.matdes.2023.112352.Google Scholar
Hartmann, B. (2009), Gaining Design Insight through Interaction Prototyping Tools., Doctoral Thesis, Stanford University.Google Scholar
Hashemi, S.M., Parvizi, S., Baghbanijavid, H., Tan, A.T.L., Nematollahi, M., Ramazani, A., Fang, N.X., et al. . (2022), “Computational modelling of process–structure–property–performance relationships in metal additive manufacturing: a review”, International Materials Reviews, Vol. 67 No. 1, pp. 1–46, https://dx.doi.org/10.1080/09506608.2020.1868889.CrossRefGoogle Scholar
ISO/ASTM. (2017), “ISO/ASTM 52910:2017(E). Standard Guidelines for Design for Additive Manufacturing.”, ISO/ASTM International, Vol. 2017 No. 23436, pp. 1–14, https://dx.doi.org/10.1520/ISO.Google Scholar
ISO/ASTM. (2018), ISO/ASTM/DIS 52902 - Additive Manufacturing - Test Artificats -- Standard Guideline for Geometric Capability Assessment of Additive Manufacturing Systems, ISO/ASTM 52902, Vol. 1.Google Scholar
Jones, A., Leary, M., Bateman, S. and Easton, M. (2021), “Effect of surface geometry on laser powder bed fusion defects”, Journal of Materials Processing Technology, Vol. 296, p. 117179, https://dx.doi.org/10.1016/j.jmatprotec.2021.117179.CrossRefGoogle Scholar
Lawrence, C. (2003), “Right-Rapid-Rough.”, ASK, Academy Sharing Knowledge., No. 13.Google Scholar
Lindwall, A. (2023), Creativity in Design for Additive Manufacturing, Luleå University of Technology.Google Scholar
McClelland, R. (2022), “Generative Design and Digital Manufacturing : Using AI and robots to build lightweight instruments”, NASA Goddard Space Flight Center.CrossRefGoogle Scholar
Meltio. (2024), “Meltio Stainless Steel 316L”.Google Scholar
Min, W., Yang, S., Zhang, Y. and Zhao, Y.F. (2019), “A comparative study of metal additive manufacturing processes for elevated sustainability”, Proceedings of the ASME Design Engineering Technical Conference, Vol. 4, pp. 1–9, https://dx.doi.org/10.1115/DETC2019-97436.Google Scholar
Nazir, A., Abate, K.M., Kumar, A. and Jeng, J.Y. (2019), “A state-of-the-art review on types, design, optimization, and additive manufacturing of cellular structures”, International Journal of Advanced Manufacturing Technology, The International Journal of Advanced Manufacturing Technology, Vol. 104 No. 9–12, pp. 3489–3510, https://dx.doi.org/10.1007/s00170-019-04085-3.Google Scholar
Nicoletto, G., Konečna, R., Frkan, M. and Riva, E. (2020), “Influence of layer-wise fabrication and surface orientation on the notch fatigue behavior of as-built additively manufactured Ti6Al4V”, International Journal of Fatigue, Vol. 134 No. October 2019, https://dx.doi.org/10.1016/j.ijfatigue.2020.105483.CrossRefGoogle Scholar
Obilanade, D., Törlind, P. and Dordlofva, C. (2022), “Surface roughness and design for additive manufacturing: A design artefact investigation”, In Proceedings of the Design Society, Cambridge University Press, Vol. 2, pp. 1421–1430, https://dx.doi.org/10.1017/PDS.2022.144.Google Scholar
Orbex, . (2023), “Satellite Launch Vehicle | Orbex Prime Micro-Launcher | Orbex”, Orbex, available at: https://orbex.space/launch-vehicle (accessed 13 September 2023).Google Scholar
Pilkey, W.D. and Pilkey, D.F. (2007), Shoulder Fillets, Peterson's Stress Concentration Factors, https://dx.doi.org/10.1002/9780470211106.ch3.CrossRefGoogle Scholar
du Plessis, A. and Beretta, S. (2020), “Killer notches: The effect of as-built surface roughness on fatigue failure in AlSi10Mg produced by laser powder bed fusion”, Additive Manufacturing, Vol. 35, https://dx.doi.org/10.1016/j.addma.2020.101424.CrossRefGoogle Scholar
Reiher, T. and Koch, R. (2016), “Product optimization with and for additive manufacturing”, Solid Freeform Fabrication 2016: Proceedings of the 27th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2016, pp. 2236–2249.Google Scholar
Relativity Space, . (2023), “Relativity Space”, Relativity Space, available at: https://www.relativityspace.com/ (accessed 13 September 2023).Google Scholar
Renjith, S.C., Park, K. and Okudan Kremer, G.E. (2020), “A Design Framework for Additive Manufacturing: Integration of Additive Manufacturing Capabilities in the Early Design Process”, International Journal of Precision Engineering and Manufacturing, Korean Society for Precision Engineering, Vol. 21 No. 2, pp. 329–345, https://dx.doi.org/10.1007/s12541-019-00253-3.CrossRefGoogle Scholar
Rismalia, M., Hidajat, S.C., Permana, I.G.R., Hadisujoto, B., Muslimin, M. and Triawan, F. (2019), “Infill pattern and density effects on the tensile properties of 3D printed PLA material”, Journal of Physics: Conference Series, Vol. 1402 No. 4, pp. 2–8, https://dx.doi.org/10.1088/1742-6596/1402/4/044041.Google Scholar
Sacco, E. and Moon, S.K. (2019), “Additive manufacturing for space: status and promises”, International Journal of Advanced Manufacturing Technology, Springer, Vol. 105 No. 10, pp. 4123–4146, https://dx.doi.org/10.1007/s00170-019-03786-z.Google Scholar
Samal, S.K., Vishwanatha, H.M., Saxena, K.K., Behera, A., Nguyen, T.A., Behera, A., Prakash, C., et al. . (2022), “3D-Printed Satellite Brackets: Materials, Manufacturing and Applications”, Crystals, Vol. 12 No. 8, pp. 1–22, https://dx.doi.org/10.3390/cryst12081148.CrossRefGoogle Scholar
Shanmukha Prasad, V., Krishna Sai Ram, B.K., Murali Krishna, K.B., Lokesh Kumar Reddy, T. and Vijay Kumar, S. (2020), “Stress concentration factors for shouldered shaft with fillet and taper loaded in tension”, International Journal of Scientific and Technology Research, Vol. 9 No. 4, pp. 184–187.Google Scholar
Thompson, M.K., Moroni, G., Vaneker, T., Fadel, G., Campbell, R.I., Gibson, I., Bernard, A., et al. . (2016), “Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints”, CIRP Annals - Manufacturing Technology, CIRP, Vol. 65 No. 2, pp. 737–760, https://dx.doi.org/10.1016/j.cirp.2016.05.004.CrossRefGoogle Scholar
Thompson, S.M., Bian, L., Shamsaei, N. and Yadollahi, A. (2015), “An overview of Direct Laser Deposition for additive manufacturing; Part I: Transport phenomena, modeling and diagnostics”, Additive Manufacturing, Elsevier B.V., Vol. 8, pp. 36–62, https://dx.doi.org/10.1016/j.addma.2015.07.001.Google Scholar
Ulrich, K.T. and Eppinger, S.D. (2012), Product Design and Development, McGraw-Hill.Google Scholar
Universität Paderborn, . (2016), “AM for satellites: Reaction Wheel Bracket”, available at: https://dmrc.uni-paderborn.de/content/innovation/am-for-satellites-reaction-wheel-bracket (accessed 19 November 2023).Google Scholar
Veritasium. (2021), “The Genius of 3D Printed Rockets - YouTube”, Veritasium, available at: https://www.youtube.com/watch?v=kz165f1g8-E&ab_channel=Veritasium (accessed 16 November 2023).Google Scholar
Zhou, L., Zhu, Y., Liu, H., He, T., Zhang, C. and Yang, H. (2021), “A comprehensive model to predict friction factors of fluid channels fabricated using laser powder bed fusion additive manufacturing”, Additive Manufacturing, Vol. 47, p. 102212, https://dx.doi.org/10.1016/j.addma.2021.102212.CrossRefGoogle Scholar