<div>The objective of this dissertation is to develop new methods in the areas of multiscale topology optimization, thermomechanical topology optimization including heat convection, and thermal-fluid topology optimization. The dissertation mainly focuses on developing five innovative topology optimization algorithms with respect to structure and multistructure coupling fluid, thermal and mechanical analysis, in order to solve customary design requirements. Most of algorithms are coded as in-house code in MATLAB.</div><div><br></div><div><div>In Chapter One, a brief introduction of topology optimization, a brief literature review and the objective is presented. Five innovative algorithms are illustrated in Chapter Two</div><div>to Six. From Chapter Two to Four, the methods with respect to multiscale approach are presneted. and Chapter Five and Six aims to contribute further research associated with</div><div>topology optimization considering heat convection. In Chapter Two, a multiphse topology optimization of thermomechanical structures is presented, in which the optimized structure is composed of several phases of prescribed lattice unit cells. Chapter Three presents a</div><div>Multiscale, thermomechanical topology optimization of self-supporting cellular structures. Each lattice unit cell have a optimised porousity and diamond shape that benefit additive</div><div>manufacturing. In Chapter Four, the multiscale approach is extended to topology optimization involved with fluid mechanics problem to design optimized micropillar arrays in</div><div>microfludics devices. The optimised micropillars minimize the energy loss caused by local fluid drag force. In Chapter Five, a novel thermomechanical topology optimization is developed, in order to generate optimized multifunctional lattice heat transfer structure. The algorithm approximate convective heat transfer by design-dependent heat source and natural convection. In Chapter Six, an improved thermal-fluid topology optimization method is created to flexibly handle the changing of thermal-fluid parameters such as external heat source, Reynolds number, Prandtl number and thermal diffusivity. The results show the</div><div>changing of these parameters lead versatile optimized topologies. Finally, the summary and recommendations are presented in Chapter Seven.</div></div><div><br></div>

Le procédé de fusion sélective « lit de poudre » (SLM) permet d'élaborer des pièces métalliques bonne matière (denses) directement à partir de la fusion de couches de poudres successives. De nombreux problèmes techniques doivent encore être surmontés pour faire du SLM un processus de fabrication entièrement viable. C'est le cas de l’état de surface et de l'apparition systématique de porosités, qui nécessitent des étapes de post-traitements. Jusqu'à présent, l'origine de la porosité reste incertaine mais est supposée être liée à la stabilité du procédé. Cette thèse propose une étude originale de l'interaction laser-poudre-bain liquide sur 316L et sur deux alliages d’aluminium (5086 et 4047) avant d’étudier les conditions de densification de la matière. Le travail de cette thèse s’articule en deux parties. Dans la première partie, une étude expérimentale de l’interaction laser-matière a été effectuée sur un banc instrumenté à partir d’imagerie par caméra rapide (>10 000 images /s). Les conditions de formation des éjections métalliques, de dénudation en poudre, l’hydrodynamique des zones fondues (dont le humping) ont été caractérisées et quantifiées. Tous ces phénomènes sont liés aux fortes densités de puissance utilisées en SLM, qui favorisent le régime de keyhole et la vaporisation. La deuxième partie de ce travail de thèse a consisté à évaluer l’origine et le taux de porosités sur une machine SLM. Une formulation analytique de la densification, dépendante d’un paramètre énergétique VED, a été validée par une étude expérimentale de l’évolution du taux de porosité, quelle que soit l’épaisseur de poudre. Un premier lien a été réalisé entre les dimensions des cordons de fusion et les conditions de densification. Enfin, une forte interaction (diffusion de Rayleigh ou absorption) a été observée entre le faisceau laser incident et les nanoparticules contenues dans la colonne de vapeur métallique, à l’origine de la dispersion importante des profondeurs de fusion. / The selective laser melting (SLM) process allows to produce dense metal parts directly from the melting of successive powder layers. However, many technical issues are still to overcome for making SLM a fully viable manufacturing process. This is the case of surface finishing and the systematic occurrence of porosities, which require post machining steps. Up till now, the origin of porosities remains unclear but is expected to be related to the stability of the process. This thesis proposes an original study of the laser-powder-melt pool interaction on 316 L and on two aluminum alloys (5086 and 4047) before studying the material’s densification conditions. The work is structured in two parts. In the first part, an experimental study of the laser-matter interaction has been carried out on an instrumented SLM setup equipped with a fast camera (>10 000 images /s). The conditions of formation of metal ejections, denudation and hydrodynamics of melt pool (including humping) have been characterized and quantified. All these phenomena are related to the high power densities used in SLM, which favor keyhole regime and vaporization. The aim of the second part of this work was to characterize the origin and the porosity fraction on an SLM machine. A first correlation has been made between the dimensions of the fusion beads and the densification conditions. A strong interaction (Rayleigh scattering or absorption) has been observed between the incident laser beam and the nanoparticles contained in the metal vapor column: this interaction is responsible for the significant dispersion of melting depths.

Additive manufacturing (AM) is currently on the verge of redefining the way we produce and manufacture things. AM encompasses many technologies and subsets, which are all joint by a common denominator; they build three dimensional (3D) objects by adding materials layer-upon-layer. This family of methods can do so, whether the material is plastic, concrete, metallic or living cells which can function as organs. AM manufacturing at the micro scale introduces new capabilities for the AM family that has been proven difficult to achieve with established AM methods at the macro scale. Electrohydrodynamic jet (E-jet or EHD jet) printing is a micro AM technique which has the ability to print at high resolution and speed by exploiting physical phenomena to generate droplets using the means of an electric field. However, when printing metallic materials, this method requires nanoparticles for deposition. To obtain a stable structure the material needs to be sintered, after which the deposited material is left with a porous structure. In contrary, electrochemical methods using the well-known deposition mechanism of electroplating, can deposit dense and pure structures with the downside of slow deposition. In this thesis, a new method is proposed to micro additive manufacturing by merging an already existing technology EHD with simple electrochemistry. By doing so, we demonstrate that it is possible to print metallic structures at the micro- and nanoscale with high speeds, without the need for presynthesized nanoparticles. To achieve this, a printing setup was designed and built. Using a sacrificial wire and the solvent acetonitrile, metallic building blocks such as lines, pillars and other geometric features could be printed in copper, silver, and gold with a minimum feature size of 200 nm. A voltage dependence was found for porosity, where the densest pillars were printed at 135-150 V and the most porous at 260 V. The maximum experimental deposition speed measured up to 4.1 µm · s−1 at 220 V. Faraday’s law of electrolysis could be used to predict the experimental deposition speed at a potential of 190 V with vexp = 1.8 µm · s−1 and vtheory = 0.8 µm · s−1. The microstructure of the pillars could be improved through lowering the applied voltage. In addition, given that Faraday’s law of electrolysis could predict experimental depositions speeds well, it gives further proof to reduction being the mechanism of deposition.

Submitted by JOSIANE SANTOS DE OLIVEIRA (josianeso) on 2018-03-19T13:06:25Z No. of bitstreams: 1 Douglas Rafael Veit_.pdf: 4241312 bytes, checksum: db46ad98d688b6b42902ae0142a9b574 (MD5) / Made available in DSpace on 2018-03-19T13:06:25Z (GMT). No. of bitstreams: 1 Douglas Rafael Veit_.pdf: 4241312 bytes, checksum: db46ad98d688b6b42902ae0142a9b574 (MD5) Previous issue date: 2018-02-27 / UNISINOS - Universidade do Vale do Rio dos Sinos / GMAP/Unisinos / As ferramentas relacionadas à Manufatura Avançada estão se desenvolvendo rapidamente e irão transformar o futuro dos sistemas de produção. O paradigma de produção será alterado para o desenvolvimento, fabricação e a comercialização de novos produtos a partir do uso destas tecnologias. Nesse contexto, uma das tecnologias tratadas com maior atenção no que tange aos sistemas produtivos é a Manufatura Aditiva. Este trabalho identificou os impactos da utilização da Manufatura Aditiva pelos sistemas produtivos e suas repercussões nos critérios competitivos. Para atender a este objetivo, foram utilizados Métodos Múltiplos de Pesquisa. Inicialmente, foi realizada uma revisão sistemática da literatura no tema em questão. Dessa revisão, emergiram proposições a respeito dos impactos e suas repercussões na competitividade das organizações, utilizados como base para o questionário das entrevistas. Este questionário foi aplicado a três grupos de entrevistados distintos: Fabricantes e Representantes da Manufatura Aditiva (Brasil e EUA), Usuários da tecnologia (Brasil, EUA e Alemanha) e Representantes de Governos nacionais (Brasil e EUA). Tanto para a literatura quanto para as entrevistas realizou-se a análise de conteúdo procurando identificar as convergências e divergências entre as análises. Ainda, para confrontar estes resultados com a prática, foram realizados dois estudos de campo e um estudo de caso. Como resultados, destaca-se que a utilização da Manufatura Aditiva é um caminho sem volta. Seus benefícios partem da redução do tempo de atravessamento desde o processo de desenvolvimento de produto até a fabricação, além da viabilidade de novos modelos de negócios. Barreiras como a velocidade de impressão e a qualidade final (aparência) devem ser solucionadas em breve, devido ao avanço da tecnologia, propiciando às organizações maior competitividade em um conjunto significativo de critérios competitivos. / The tools related to Advanced Manufacturing are developing rapidly and will transform the future of production systems. From these technologies the production paradigm will be changed for the development, manufacture and commercialization of new products. In this context, one of the technologies most carefully addressed in production systems is Additive Manufacturing. This research aimed to identify the impacts of the use of the Additive Manufacturing on the production systems and its repercussions on the competitive criteria. To achieve this goal, Multiple Research Methods were used. Initially, a systematic literature review on the subject was carried out. From this review, propositions emerged about the impacts of the additive manufacturing on the production systems and their repercussions on the competitiveness of organizations. These propositions were the basis for the elaboration of the interview questionnaire, which was applied to three different groups: Manufacturers and Representatives of the Additive Manufacturing (Brazil and USA), Users of the technology (Brazil, USA and Germany) and Representatives of national governments (Brazil and USA). For both the literature and the interviews findings, content analysis was carried out in order to identify the convergences and divergences between them. In order to compare these results with the empirical reality, two field studies and one case study were carried out. As a result, it is emphasized that the use of Additive Manufacturing is a path with no return. Its benefits include the reduction of lead time, from the product development to the manufacturing product development, and the viability of new business models. Barriers such as speed of print and final quality (appearance) should be solved soon, due to the technology improvement, giving organizations greater competitiveness in a significant set of criteria.

Laser Sintering (LS) is a powder based Additive Manufacturing (AM) technology capable of producing near-net shape objects from 3D data. The benefits of LS include almost unlimited design freedom and reduced material waste, however the number of commercially available materials are limited, with materials traditionally being optimised for the process using a trial and error method and material development being led by previous research into polyamide (PA). There is a desire for greater material choice in LS, particularly high performance polymers. The EOSINT P800 by AM systems manufacturer EOS GmbH is the first commercially available high temperature laser sintering (HT-LS) system capable of working high performance polymers; a PolyEtherKetone (PEK) known by the trade name HP3 PEK is the first material offered by EOS for use with the system. This research project undertakes to characterise the EOSINT P800 and HP3 PEK material with different thermal histories. Experimental work focusses on establishing material properties such as size and shape, crystallinity and decomposition. Characterisation of coalescence behaviour and comparison with theoretical models for viscous sintering is presented as a less experimentally intensive method of understanding how a material will behave during the LS process. A map of temperatures inside the powder bed in the EOSINT P800 is created for the first time and compared with output from on-board temperature sensors in the system, demonstrating the thermal distribution within the bed during building, and explaining differences between as-received and used powder. The results demonstrate that material and process characterisation methods are useful for understanding how and why a high temperature laser sintering material behaves the way it does. The behaviour of HP3 PEK observed during experimental work indicates that guidelines based on LS of PA are too restrictive as indicators of suitability for LS and newer systematic approaches are potentially better suited for qualification of HT-LS polymers. The novel method for mapping thermal distribution inside the LS system documented here shows the limitations of current hardware to effectively process high performance polymers. Overall, the finding of this research project is that understanding of material and process cannot be considered in isolation but combined have the potential to reduce the amount of trial and error required during qualification of new materials and increase the range and variety of polymers available for LS and HT-LS.

Additiv tillverkning (AT) eller 3D-utskrivning är en teknologi som har berömts den senaste tiden och förutsägs kommer att förändra hela tillverkningsindustrin. Dessa termer hänvisar båda till ett antal tillverkningstekniker där ett objekt framställs skikt för skikt genom att successivt tillföra material i tunna lager.Baserat på en litteraturstudie och intervjuer med experter inom området undersöker denna studie möjligheten att använda AT inom företaget CJ Automotive (CJA) vilket är en underleverantör inom fordonsindustrin som tillverkar olika slags pedalsystem. Rapporten beskriver additiv tillverkning, dess fördelar och olika användningsområden. Olika AT-tekniker, AT-material och välkända 3D-skrivartillverkare presenteras. Signifikanta fakta rörande både kvalitet, kostnad och teknik redogörs för. Även en jämförelse mellan olika tekniker redovisas.Denna rapport innehåller riktlinjer för hur ett företag ska tänka och vilka faktorer som är viktiga vid val av rätt 3D-skrivarteknik. Studien pekar på att det finns många fördelar med att utnyttja 3D-skrivare under utvecklingsprocessen på företaget. Detta kommer att påskynda utvecklingsprocessen och eventuellt förbättra produkterna till följd av mer flexibilitet och designmöjligheter. Slutligen föreslås två AT-tekniker som tycks vara de lämpligaste med tanke på företagets verksamhet. / Program: Högskoleingenjörsexamen i Maskiningenjörprogrammet - Produktutveckling

3D printing a CAD modelnormally requires conversion into a polygon mesh, usually an STL-file, in orderto be able to load the model in the slicer. This conversion destroys roundsurfaces and replaces them with flat surfaces. Slicing a polygon mesh resultsin one or more polygons, consisting of a number of straight lines. This canaffect both dimensional accuracy and surface smoothness. Modern 3D-printerscan, in addition to straight lines, handle arcs. However, today’s commonslicers can not generate arcs as the input does not contain any curvedfeatures. This project aims at finding an alternative solution. By directslicing of CAD models the slices can contain arcs, and the slicer can producearc commands for the 3D-printer. During this project a prototype slicer isconstructed as a proof of concept. The prototype handles STEP-files as inputand creates both linear and circular movement for the 3D-printer. The resultsshow that both the intermediate files (STEP/STL) and the resulting G-code filescan get smaller, yet preserving the original shape, by using this method. Theproposed solution has a positive effect on the 3D-printing workflow as well, asthe intermediate files can be imported back into the CAD system. The projectconcludes that there is possibly a bright future for direct slicing, but thereare more problems to solve before it can become reality.

<div>Fused deposition modeling (FDM) represents one of the most common techniques for rapid proto-typing in additive manufacturing (AM). This work applies image based thermography to monitor the FDM process in-situ. The nozzle temperature, print speed and print orientation were adjusted during the fabrication process of each specimen.</div><div>Experimental and numerical analysis were performed on the fabricated specimens. The combination of the layer wise temperature profile plot and temporal plot provide insights</div><div>for specimens fabricated in x, y and z-axis orientation. For the x-axis orientation build possessing 35 layers, Specimens B16 and B7 printed with nozzle temperature of 225 ➦C and</div><div>235 ➦C respectively, and at printing speed of 60 mm/s and 100 mm/s respectively with the former possessing the highest modulus, yield strength, and ultimate tensile strength. For the y-axis orientation build possessing 59 layers, Specimens B23, B14 and B8 printed with nozzle temperature of 215°C, 225°C and 235°C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and yield strength, while the latter the highest ultimate tensile strength. For the z-axis orientation build possessing 1256 layers, Specimens B6, B24 and B9 printed with nozzle temperature of 235°C, 235°C and 235°C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and ultimate tensile strength, while B24 had the highest yield strength and B9 the lowest modulus, yield strength and ultimate tensile strength. The results show that the prints oriented in the y-axis orientation perform relatively better than prints in the x-axis and z-axis orientation.</div>

In recent years, additive manufacturing (AM) has become an increasingly promising method used for the production of structural metallic components. There are a number of reasons why AM methods are attractive, including the ability to produce complex geometries into a near-net shape and the rapid transition from design to production. Ti-6Al-4V is a titanium alloy frequently used in the aerospace industry which is receiving considerable attention as a good candidate for processing via electron beam additive manufacturing (EBAM). The Sciaky EBAM method combines a high-powered electron beam, weld-wire feedstock, and a large build chamber, enabling the production of large structural components. In order to gain wide acceptance of EBAM of Ti-6Al-4V as a viable manufacturing method, it is important to understand broadly the microstructural features that are present in large-scale depositions, including specifically: the morphology, distribution and texture of the phases present. To achieve such an understanding, stereological methods were used to populate a database quantifying key microstructural features in Ti-6Al-4V including volume fraction of phases, a lath width, colony scale factor, and volume fraction of basket weave type microstructure. Microstructural features unique to AM, such as elongated grains and banded structures, were also characterized. Hardness and tensile testing were conducted and the results were related to the microstructural morphology and sample orientation. Lastly, fractured surfaces and defects were investigated. The results of these activities provide insight into the process-structure-properties relationships found in EBAM processed Ti-6Al-4V.

Nos últimos anos, a aplicação de tecnologias de manufatura aditiva tem crescido, estendendo seus benefícios para áreas diversas, como saúde, e encurtando o tempo de desenvolvimento de produto. Contudo, são encontrados apenas fabricantes nacionais de versões \"open-source\" de baixo custo de tecnologias de modelagem por fusão deposição (FDM), não existindo desenvolvedor de uma tecnologia nacional. Em função disto, o objetivo principal deste trabalho é apresentar e validar uma nova concepção de processo de fabricação aditiva. Esta proposta consiste na geração seletiva de compósito de celulose e acrílico através de fonte coerente de luz UV. Para isto, foram realizados estudos referentes a duas áreas principais, desenvolvimento de material e validação da concepção de processo proposto. Para o desenvolvimento de material, foram estudados materiais fotopoliméricos a base de acrilatos de forma a ser obtida uma formulação de material adequada para ser validado o processo. Da mesma forma, a seleção do material celulósico empregado foi realizado a partir da caracterização de materiais celulósicos laminados (papéis) comumente encontrados no mercado. Adicionalmente, foi identificado potencial de viabilidade preliminar da proposta ao longo da caracterização do compósito, visto que foi avaliada a aderência entre camadas, resistência mecânica à tração, resistência à água e microestrutura do compósito. Após o desenvolvimento do material, foi desenvolvido o projeto preliminar do equipamento de validação da proposta, assim como a fabricação de um protótipo e sua calibração. Foram realizados estudos de otimização para implementação do projeto do sistema de posicionamento, assim como dimensionamento de \"error Budget\" e custo relativo de equipamento. Foi também desenvolvido sistema de deposição de material polimérico, sistema de polimerização e alimentação de material, sendo realizados estudos de caracterização e validação do processo proposto. Foram identificados os efeitos principais dos principais parâmetros de processo para a largura da linha de polimerização, interferência da formação de compósito para camadas anteriores e, por fim a construção de corpo de prova. Através destes estudos, foi possível identificar a viabilidade funcional da proposta, sendo observadas as vantagens e desvantagens desta nova concepção em relação aos principais processos de fabricação aditiva no mercado. / In recent years, the application of additive manufacturing technologies has grown, extending its benefits to diverse areas such as health, and shortening the time product development. However, national manufacturers are only found to provide versions of open-source and low cost FDM technologies, highlighting the absence of a national technology developer. Due to that, the main goal of this work is to present and evaluate a novel concept of additive manufacturing process. This proposal consists in selectively generate composite of cellulose and acrylic through a coherent UV light source. For this, studies have been conducted concerning two main areas, material development and validation of proposed process. For the development of material, we have studied photopolymeric materials based on acrylates so as to obtain a composition of material suitable for validating the process. Likewise, the selection of cellulosic substrate was made from the characterization of laminated cellulosic materials (sheet of paper) which are commonly found at market. Additionally, we identified the potential feasibility of the proposal along the preliminary characterization the composite, whereas it was evaluated the adhesion between layers, tensile strength, water resistance and microstructure of the composite. After development the material, it was developed a preliminary design of equipment for validation of proposal, in addition to fabricating and calibrating a prototype. Studies were performed to optimize and implement the mechanical design of the positioning system as well as sizing error Budget and relative cost of equipment. It was also developed the systems of poylmerization, photopolymeric material deposition, and feed of substrate, being conducted studies for the characterization and validation of proposed process. We identified the main effects of the main process parameters on the polymerization line width, interference of the formation of composite layers for and previous layers, and the construction of the test ix body. Through these studies, it was possible to identify the functional feasibility of the proposal, being observed the advantages and disadvantages of this novel design in comparison with the main additive manufacturing process in the market.