SEARCH RESULT

Shaped metal deposition (SMD) is a relatively new additive layered manufacturing method. It is a novel technique to build net-shaped or near-net-shaped metal components in a layer-by-layer manner via applying metal wire and selection of a heat source such as laser beam, electron beam, or electric arc. SMD process is preferable as an alternative to traditional manufacturing methods especially for complex featured and large scale solid parts manufacturing and it is particularly used for aerospace structural components, manufacturing and repairing of dies/molds. TIG welding-based SMD method is implemented by depositing continuous wire melted via heat. In this study, the overhang (self supporting) angle in TIG welding-based shape metal deposition process is investigated. The overhang angles are the angles at which a 3D printer can build tapered (overhang) surfaces without the need to supporting material below the printing layer. The material, bead height, TIG weld parameters and the environment temperature (cooling rate of printed layer) are the parameters which affect the overhang angle. The results show that the maximum overhang angle is also dependent on the temperature of the previous layer. For the selected set of process parameters, the maximum overhang angle is found as 28 , if o the temperature of the previous layer is cooled to 150 C before the subsequent layer is deposited.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

Ömer Eyercioğlu Yusuf Atalay Mehmet Aladağ Oğuzhan Yılmaz

Nowadays, lightening of structural and mechanical parts of space vehicles while preserving the design and functional requirements is one of the main challenges for space researches. It is obvious that launching any additional mass of one-kilogram load to space costs approximately 20K Euros according to the current tariff. Topology optimization is one of the most popular methods in structural optimization as it does not only change the size and shape of a given design but also it changes the material distribution while fulfilling the boundary conditions. In this study, an organic geometrical modelling approach and a topology optimization for lightening of a satellite part that is expected to be able to use in a spacecraft has been applied. All design approaches are taken into considerations for Additive Manufacturing. A topology optimization tool of a commercial finite element software has been used for an early optimized topology and an organic geometrical approaches have been performed in order to satisfy the structural (strength and stiffness) and modal (natural frequency) requirements. Biomimicry has been used in organic design. Tree-branch geometries have been used to support the main bodies and increase the natural frequency. An elephant foot shape has been used on the bracket contact surfaces to the ground to increase the stiffness of the body. The proposed design exhibited very promising results, such as 45.2% weight reduction and 57.7% von-misses stresses reduction when powder bed fusion process is to be used for manufacturing.

International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019

M. Emin BADIR E. SÖĞÜTKIRAN Akın DAĞKOLU Oğuzhan Yılmaz