It is compelling to realize that the additive manufactured part using wire feeding type directed energy deposition (DED) process is subjected to undesired thermal effects, and induced residual stress during the manufacturing process. In order to improve the quality of the manufactured part, the distributions of temperature and residual stress have to be understood to manage the results of the processing of these materials. The objective of this paper is to investigate the influence of the angle of corner deposition on the distributions of temperature and residual stress of the Ti-6Al-4V deposited bead, and the substrate via thermo-mechanical finite element analyses (FEAs). In the same fashion, the formation of the heat affected zone (HAZ) and the stress influenced region (SIR) are estimated from the measured results of the FEAs. Equally important, it can be stated that from the estimated HAZ and SIR regions, the overlapping of undesired thermal effects and residual stress between two beads fabricated by the wire feeding type DED process can be avoided at the design stage.
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Estimation Method of Interpass Time for the Control of Temperature during a Directed Energy Deposition Process of a Ti–6Al–4V Planar Layer Bih-Lii Chua, Dong-Gyu Ahn Materials.2020; 13(21): 4935. CrossRef
Investigation of Influence of Laser Parameters and Powder Porosity on Thermal Characteristics in the Powder Bed of a SLM Process Kwang-Kyu Lee, Ho-Jin Lee, Hyun-Sik Kim, Dong-Gyu Ahn, Yong Son Journal of the Korean Society for Precision Engineering.2019; 36(8): 761. CrossRef
Wire feeding type directed energy deposition (DED) process is able to produce metal parts with high density at high deposition rate. However, the parts are subjected to high residual stresses and distortion due to its large heat input. In order to simulate the thermal stress, a proper heat input parameter is required. The goal of this paper is to investigate the efficiency and penetration depth of the applied heat flux in the DED process. The estimation method for the penetration depth and efficiency of applied heat flux is proposed using the thermal finite element analyses (FEAs). A finite element model is developed according to the cross sectional profile of the actual deposited beads. A top-hat volumetric heat flux is adopted to simulate the transient thermal phenomenon of the laser based wire feeding type DED process. The estimated heat affected zone (HAZ) from the FEAs is compared with the experimental results in order to estimate the proper efficiency and penetration depth of the laser beam for each condition of DED process.
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Process Kwang-Kyu Lee, Dong-Gyu Ahn, Woo-Sung Kim, Ho-Jin Lee Journal of the Korean Society of Manufacturing Process Engineers.2020; 19(8): 56. CrossRef
Estimation Method of Interpass Time for the Control of Temperature during a Directed Energy Deposition Process of a Ti–6Al–4V Planar Layer Bih-Lii Chua, Dong-Gyu Ahn Materials.2020; 13(21): 4935. CrossRef
A Study on Activation Algorithm of Finite Elements for Three-Dimensional Transient Heat Transfer Analysis of Directed Energy Deposition Process Bih-Lii Chua, Ho-Jin Lee, Dong-Gyu Ahn, Yeqing Wang International Journal of Precision Engineering and Manufacturing.2019; 20(5): 863. CrossRef
Influences of deposition strategies on thermo-mechanical characteristics of a multilayer part deposited by a wire feeding type DED process Bih Lii Chua, Dong-Gyu Ahn, Jae-Gu Kim Journal of Mechanical Science and Technology.2019; 33(12): 5615. CrossRef
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Influence of process parameters on temperature and residual stress distributions of the deposited part by a Ti-6Al-4V wire feeding type direct energy deposition process Bih Lii Chua, Ho Jin Lee, Dong-Gyu Ahn, Jae Gu Kim Journal of Mechanical Science and Technology.2018; 32(11): 5363. CrossRef
Influence of Angle of Corner Deposition on Temperature and Residual Stress Distributions in the Vicinity of the Deposited Region by a Ti-6Al-4V Wire-Feeding Type of Direct Energy Deposition Process Bih Lii Chua, Ho Jin Lee, Dong-Gyu Ahn, Jae Gu Kim Journal of the Korean Society for Precision Engineering.2018; 35(9): 853. CrossRef
The thermoforming process has been widely used to manufacture medium- and large-sized plastic parts because of the relatively low cost and high productivity, as compared with other plastic forming processes. One of current salient issues of thermoforming industries is the reduction of trial and error during the production of the thermoformed product. Hence, there is a significant increasing interest in the thermoforming analysis by the thermoforming industries. The goal of this paper is to investigate a methodology of the three-dimensional thermoforming analysis for medium- and large-sized plastic parts. There is a discussion about methodologies of thermoforming analysis, as well as material modeling, and three-dimensional finite element analysis. Furthermore, there is an examination, through case studies, about the applicability of the proposed methodology concerning the thermoforming analysis.
Recently, several researchers made their endeavor to manufacture the photobioreactor(PBR) with characteristic shapes form vacuum and blow forming process. Hence, behaviors of the transparent polycarbonate(PC) plate in the high temperature region should be examined to obtain the desired PBR case via vacuum and blow forming processes. The aim of this paper is to investigate tensile behavior of PC plate in the high temperature. Various tensile tests were performed using high temperature tensile testing machine. The influence of tensile speed, thickness and ambient temperature on tensile behavior in the high temperature was examined. The flow stress and tensile strength augmented when the tensile speed increased. In order to obtain proper flow curves with strain rate effects for different temperature of specimen, G’sell-Jonas model was adopted. The material constants of the G’sell-Jonas model were estimated. The flow curves of the PC plate considering the tensile speed, specimen thickness and temperature were obtained.
Adhesive bonding and plastic welding have been widely used to join two plastic materials together. The goal of this paper is to determine a proper joining technology of a pair of flat panel (FP) photobioreactor (PBR) case. The material of the FP PBR case is polycarbonate (PC) plate. Two types of adhesion, including acryl adhesive and two-part epoxy adhesive, as well as two types of plastic welding technology, including ultrasonic welding and thermal welding, are employed for joining of PC plates. In order to influence of the adhesion and welding conditions on the joining characteristics of the PC plates in operational conditions of the FP PBR case, the morphology in the vicinity of the joined region as well as the water and pressure resistance characteristic are investigated. In addition, the variation of the bonding strength of the joined region and deformation behaviors in the vicinity of the joined region according to the adhesion and welding conditions is examined via the lap-shear test. From the result of basic experiments, proper joining technologies are chosen. Using the chosen joining technologies, the FP PBR case are fabricated to perform full-scale durability experiment. The results of the full-scale durability experiment have been shown that the chosen joining technologies can be applicable to fabricate the FP PBR case.
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