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Understanding Additive Manufacturing Part Performance Through Modeling and Laboratory Experiments

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Conference

2015 ASEE Annual Conference & Exposition

Location

Seattle, Washington

Publication Date

June 14, 2015

Start Date

June 14, 2015

End Date

June 17, 2015

ISBN

978-0-692-50180-1

ISSN

2153-5965

Conference Session

Integrating Curriculum and Labs in ET Programs

Tagged Division

Engineering Technology

Page Count

13

Page Numbers

26.1619.1 - 26.1619.13

DOI

10.18260/p.24955

Permanent URL

https://peer.asee.org/24955

Download Count

325

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Paper Authors

biography

Ying Zhang Texas A&M University

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Ying Zhang is a fourth year PhD student in Mechanical Engineering department at Texas A&M University, working under the supervision of Dr. Jhywen Wang. Currently, she is a graduate teaching assistant for Strength of Material lab in Engineering Technology Industrial Distribution department. She has been a TA for this class since spring 2013. Her doctoral research is focused on fabrication, Finite Element simulation, and mechanical modeling of layer-by-layer composites. She is also interested in material performances and surface damage of polymer coated sheet metal. She holds a master’s degree and Bachelor’s degree in Mechanical Engineering in Wuhan University of Technology, Wuhan, China, where she designed an automatic temperature control system for salt-bath furnace as well as studied the corrosion resistance and surface protection of dies. She is currently a member of ASME and SWE.

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Jyhwen Wang Texas A&M University Orcid 16x16 orcid.org/0000-0001-9016-0566

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Jyhwen Wang joined the Department of Engineering Technology and Industrial Distribution at Texas A&M University after working for 10 years as a researcher and R&D manager in industry. He teaches mechanics of materials, mechanical design applications and manufacturing processes. His research interest is in design and analysis of material processing technologies. He received his Ph. D. degree in mechanical engineering from Northwestern University.

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Monish S. Mamadapur Alcon Research, Ltd.

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Monish S. Mamadapur received his Bachelor of Engineering degree in Mechanical Engineering from Rashtreeya Vidyalaya College of Engineering, Bangalore, under Visvesvaraya Technological University, Belgaum, India in 2005. He entered the Mechanical Engineering program at Texas A&M University in September 2005 and received his Master of Science degree in December 2007. He is currently working as a Senior FEA Engineer, R&D at Alcon Research, Ltd.

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Abstract

Understanding additive manufacturing part performance through modeling and laboratory experimentsAdditive manufacturing (AM) has attracted extensive attention in recent years. Earlier AMtechnologies were considered as a means for rapid prototyping. With advances in machine designand processing technology, various AM machines claim to have the capability of producingfunctional parts that can meet certain performance requirements. As most of the AM parts arebuilt layer by layer, it is clear that parts manufactured from AM processes would performdifferently compared to parts manufactured from conventional processes such as casting andinjection molding. As students often rely on AM for part fabrication in course and capstoneprojects, and industries could adopt AM to produce components for their products, there is aneed for students to understand the performance of parts manufactured from AM processes.The Strength of Materials course is a critical part of a typical engineering and engineeringtechnology curriculm where students acquire basic knowledge and analytical skills formechanical design. With a focus on experiential learning, the Strength of Material course in______ program at ______ University consists of hands-on labortary exercises. Students areorganized in teams to install strain gages and conduct experiments to enhance their learning ofabstract concepts. To introduce students to the mechanical behavior of AM parts, it is appropriateto incorporate an AM laboratory exercise in the course.This paper presents an effort of developing and implementing laboratory materials for students toconduct experiments with AM parts. Fused deposition modeling (FDM) is one of the mostpopular AM technologies. In the FDM process, partially melted filament is extruded from anozzle. The motion of the nozzle is controlled to deposit the material strand by strand and layerby layer. As such, the parts built/printed using FDM is highly anisotropic. In this developmenteffort, tensile specimens of Acrylonitrile Butadiene Styrene (ABS) are printed from threedifferent build configurations. In the first lab, students are assigned to characterize the tensilebehavior of the specimens. The test results are then compared to the bulk ABS property. In thefollow-up lab, the constitutive model of AM ABS, adopted from a graduate research project, ispresented to students. New parts including a beam and an L bracket are fabricated using theFDM process. The beam and the bracket are then tested under three-point-bending and combinedbending and torsion, respectively. Students are instructed to compare the performance of the AMparts to that of the parts with bulk ABS property. Student feedback of the learning experience issummarized. The laboratory exercise can enhance students’ understanding of AM partperformance. The developed materials can be adopted by others teaching in engineeringtechnology programs..

Zhang, Y., & Wang, J., & Mamadapur, M. S. (2015, June), Understanding Additive Manufacturing Part Performance Through Modeling and Laboratory Experiments Paper presented at 2015 ASEE Annual Conference & Exposition, Seattle, Washington. 10.18260/p.24955

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