Sharif Digital Repository

In recent years, Additive Manufacturing has been extensively used by various industries. These manufacturing processes produce components in a layer-by-layer manner; therefore, they do not impose any geometric constrains to engineers and provide designers with the freedom to design components. Nowadays, one of the primary goals of all industries is to utilize as few raw materials as possible; this way they can deal with the shortage of raw materials and improve their efficiency. Consequently, they implement topology optimization algorithms to design and produce their components. However, topology optimization algorithms result in complicated geometries that can only be fabricated by AM.... 

In the traditional process planning, the expert decides upon the production process for a product by considering the previous cases and by decomposing, analysis and interpreting the shape of the product in terms of more familiar previous cases. In recent decades and by developments in the disciplines of the artificial intelligence, mass customization, cloud manufacturing and additive manufacturing, a necessity for process planning systems which need less human intervention by intelligent interpretation of the shape and consideration of the available data from previous productions, has emerged. Inspired by the traditional process planning by human expert, and considering the overall process... 

Additive manufacturing (Simply called A.M.) is a group of manufacturing technologies that is developing rapidly and is being used widely in some industries like car manufacturing, Aerospace and producing Biomedical devices, In a way that some researchers believe that A.M. methods will change the future of manufacturing. One of the most important A.M. techniques is the Selective Laser Sintering (SLS) method that is mostly used in industrial applications. A SLS machine has a lot of sub systems and mechanisms that have key role in the Laser Sintering process. One of the mechanisms of SLS machine is the Powder Dispensing mechanism that produce layers of unsintered powder as thin as 100 microns... 

Wire arc additive manufacturing (WAAM) is used to manufacture parts in large scale, low cost, and at high rate of production. One of the problems of this technique is the creation of residual stress in the produced components. The aim of this study is to investigate the efficiency of procedures reducing the amount of residual stress to ameliorate the WAAM technique. In this research, the WAAM method and the procedures for reducing the amount of residual stress are explained. Also the advantage of this technique is presented. Due to the enormous amount of parameters and for the aim of saving time and expense, the simulation method is used. The accuracy of the simulation was checked with... 

In the process of Additive manufacturing for metals, the ability to predict and control the microstructure can reduce the need for subsequent heat treatment and accelerate the component quality assessment process. The ability to predict and control the microstructure of materials in the laser deposition method needs to understand the thermal conditions during the solidification process. For this purpose, the present study investigated the relationship between cooling rate and temperature gradient during local solidification, and control parameters of the laser deposition process such as power, beam radius, scanning speed and strategy of laser, ambient temperature and preheating temperature.... 

One of the major challenges in Additive Manufacturing is the creation of residual stresses due to the high temperature gradient in the solidification zone. This will cause problems such as cracks in the structure, metallurgical defects as well as deformation and dimensional accuracy reduction in the finished product. The purpose of this study is to perform mathematical modeling and computer simulation of the selective laser melting process (SLM) to predict these stresses as well as identify the effective parameters on this phenomenon. The conditions were adjusted in this model with the actual coefficients of the device. Additionally, the powder used in this project is Ti6Al4V material. By... 

Direct Metal Deposition is one of the methods of Additive manufacturing that has seen the most spread in recent years. In this method metal powder is directed towards the free surface of the workpiece through a nuzzle, and is simultaneously heated to become molten in a melting pool by a laser beam and begins the deposition process. One of the parts that make up a DMD system is powder feeding nuzzle. These nuzzles usually encounter a similar fundamental problem: that the effect of gravity on the stream of metal powder and the carrier fluid causes this stream to deviate from its intended position. To prevent this, nuzzles are usually designed with a fixed downward angle and the angle of the... 

Additive manufacturing (AM)has gained extensive industrial and research attention in recent years. Reducing manufacturing waste, lead-time and costs and the ability to build surfaces and parts with complex shapes, assemblies all at once or parts with internal features are some benefits of AM. However, complex error generation mechanisms underlying AM digital physical chains are likely to result in geometrical inaccuracies of the final product, thus posing significant challenges to design and tolerancing for AM. Therefore, predictive modeling of shape deviations is critical for AM. With increasing volumes and varieties of data, machine learning has gained extraordinary popularity due to its... 

In various industries such as aerospace, biomedicine and automobile manufacturing, they seek to manufacture light parts with complex geometry and acceptable mechanical properties. Additive manufacturing processes have gained a special place in the field of rapid prototyping, reverse engineering, mold production, etc. brought It is very important to know the mechanical properties, especially the fatigue behavior of the parts obtained by this method. In this research, the stress-fatigue life graph of parts made of Ti-6Al-4V (grade 5), which is one of the most widely used alloys in aerial structures, was extracted by selective laser melting. For this purpose, several standard fatigue test... 

Additive manufacturing enables fabricating lattice structures with tailored mechanical responses based on lattice materials. Full exploitation of such a possibility requires reliable and efficient mechanical analysis tools to be explored by topology optimization algorithms for designing the interior architecture of the structures to meet the desired mechanical behavior. However, detailed mechanical analysis of lattice-based structures using the conventional finite element approach is prohibitively expensive due to lattices’ complex and fine features that demand adopting very fine space discretization. As an alternative, equivalent models based on the homogenization principle have widely been... 

Selective Laser Melting (SLM) process is a powder-based metal Additive Manufacturing (AM) technique. This developing industry has many advantages like generation of geometrically complex shapes with high density. High Cost, production and characterization of powders, limited material choices and process parameters optimization are some of the challenges associated with SLM. Stainless steel 316L due to its unique properties, like corrosion resistance, high strength, biocompatibility, availability and cost is indeed a commonly used material in SLM. In this research, the characterization of the powder produced by the flame spraying device, which is a new method, was discussed. Wire with 3mm... 

Flexible cones are one of the latest bone loss treatment methods in the ever-increasing revision total knee arthroplasty. This study is conducted to assess the biomechanical performance of the tibial flexible cellular cones in enhancing the initial stability of the implant system through the analysis of implant micromotion, as well as minimizing stress shielding through the analysis of strain distribution in the bone. The research evaluates the impact of various geometrical variables, including the thickness of the porous wall, the presence, type, width, number, and location of the inner solid wall notches on the spring stiffness and stress distribution of these cones. The research... 

A decade after discovery of graphene, the unique properties and characteristics of two-dimensional materials, particularly an emerging family of carbides and nitrides (MXenes), have attracted the attention of researchers. MXenes are two-dimensional structures of two or more layers of transition metals, with interstitial carbon and/or nitrogen atoms, with exceptional properties such as high specific surface area, excellent elastic modulus, metallic conductivity, and various termination groups. These properties can be altered by various factors, including chemical composition and synthesis processes, and any changes in these factors significantly affect the properties of MXene sheets. In this... 

Today, the additive manufacturing process is one of the most important manufacturing processes. In the additive manufacturing process, the mass of the parts is directly related to the printing duration, in addition to the costs of consumables. On the other hand, the use of lighter parts in industries, such as the aviation, is one of the important requirements of those industries, and topology optimization is needed to reduce the consumables and the mass of the parts. Also, since in the optimal design of engineering parts, more than one design objective is usually considered, the multi-objective optimization of topology is of great importance. The Moving Morphable Components is one of the new...