Thesis supervisor: Csaba Felhő
Location of studies (in Hungarian): Institute of Manufacturing Science Abbreviation of location of studies: GYT
Description of the research topic:
Additive manufacturing (AM) also known as 3D printing or rapid prototyping, is getting more interest because of the significant increase in the requisition for high-performance materials and increased functionalities and complexities in a geometrical design. There are many different kinds of 3D printing technologies on the market, with their own capabilities and limitations.
Nowadays, additive manufacturing has been considered an effective production technology, and it got a major position in the manufacturing sector with the development of technology. With several benefits, additive manufacturing processes have been used in almost all areas, ranging from the aerospace, automotive, medical, marine/oil and gas, and electronics industries, to consumer applications and the food industry, etc. The main goal of this research is to work out a fundamental, systematic design and validation of a novel concept of engineered 3D layered composites as a new hybrid material, for future uses in applications where a controlled heat flux is a must to limit product degradation in heavily loaded sliding contacts i.e., the case of brake systems, where the break-pads are exposed to such extreme – mechanical and thermal at the same time – loadings. As a check of feasibility, prototyped samples are tested under lab conditions simulating operational conditions of brake systems of large importance in transportation. The conceptual 3D-geometry of these composites will allow to combine high strength and stiffness to weight-ratio, tailored thermal properties, and durability thanks to high wear resistance and low friction.
The unique capabilities of additive manufacturing (AM) include the shape complexity, in that it is possible to build virtually any shape, the hierarchical complexity, in that hierarchical multiscale structures can be designed and fabricated from the microstructure through geometric meso-structure (sizes in the millimeter range) to the part-scale macrostructure, the material complexity, in that material can be processed one point, or one layer, at a time, and, at last, but not at least, the functional complexity, in that fully functional assemblies and mechanisms can be fabricated directly using AM processes. These unique capabilities enable new opportunities for customization, very significant improvements in product performance, multifunctionality, and lower overall manufacturing costs.
Main tasks to be solved during the research:
1) Literature review about AM for layered composites
2) Geometry design and optimization
3) Discuss what types of experimental tests should be performed in the laboratories for the selected geometry (minimum 2 tests).
4) Theoretical analysis (FEM)
5) 3D printing of the given geometry by using the available AM technique(s).
6) Investigation on the post-AM processing needs of the parts (e.g. heat treatment, coating, grinding, etc.)
7) Make the same tests again in laboratories (experimental tests)
8) Compare both test results (FEA and experimental)
9) Structural optimization
10) Final tests on the optimized geometry.
Recommended reading:
1. Bhaskar Dutta Sudarsanam Babu Bradley Jared: Science, Technology and Applications of Metals in Additive Manufacturing, Elsevier, 2019, p.354
2. Juan Pou, Antonio Riveiro and Paulo Davim: Additive Manufacturing: Handbooks in Advanced Manufacturing, Elsevier, 2021, p. 768
3. K.R. Balasubramanian and V. Senthilkumar: Additive Manufacturing Applications for Metals and Composites, IGI Global, 2020, p. 348
4. Manoj Gupta: 3D Printing of Metals, MDPI, 2019, p. 138.
5. Dhinakaran V., Varsha Shree M. , Swapna Sai M. and Rishiekesh Ramgopal: Additive Manufacturing and Its Need, Role, Applications in the Automotive Industry in: Handbook of Research on Advancements in Manufacturing, Materials, and Mechanical Engineering, 2021, p.10.
6. Felhő, Cs ; Sándor, T ; Nagy, M K ; Tóth, G ; Szentesi, A: Geometrical Modeling Techniques for Rapid Prototyping Methods, microCAD 2003, Section M: International Scientific Conference, Miskolc, Hungary, University of Miskolc (2003) pp. 179-184.
7. Felhő, Cs ; Szentesi, A: Modeling of RPT, Proceeding of the 11th International Conference on Tools : ICT-2004, Miskolc, Hungary, University of Miskolc, (2004) pp. 297-302.
8. Felhő, Cs: Manufacturing of metal parts with rapid prototyping processes, ACTA MECHANICA SLOVACA 12: 4A, pp. 79-84. (2008
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