Matching Items (27)
Description
The advancements in additive manufacturing have made it possible to bring life to designs
that would otherwise exist only on paper. An excellent example of such designs
are the Triply Periodic Minimal Surface (TPMS) structures like Schwarz D, Schwarz
P, Gyroid, etc. These structures are self-sustaining, i.e. they require minimal supports
or no supports at all when 3D printed. These structures exist in stable form in
nature, like butterfly wings are made of Gyroids. Automotive and aerospace industry
have a growing demand for strong and light structures, which can be solved using
TPMS models. In this research we will try and understand some of the properties of
these Triply Periodic Minimal Surface (TPMS) structures and see how they perform
in comparison to the conventional models. The research was concentrated on the
mechanical, thermal and fluid flow properties of the Schwarz D, Gyroid and Spherical
Gyroid Triply Periodic Minimal Surface (TPMS) models in particular, other Triply
Periodic Minimal Surface (TPMS) models were not considered. A detailed finite
element analysis was performed on the mechanical and thermal properties using ANSYS
19.2 and the flow properties were analyzed using ANSYS Fluent under different
conditions.
that would otherwise exist only on paper. An excellent example of such designs
are the Triply Periodic Minimal Surface (TPMS) structures like Schwarz D, Schwarz
P, Gyroid, etc. These structures are self-sustaining, i.e. they require minimal supports
or no supports at all when 3D printed. These structures exist in stable form in
nature, like butterfly wings are made of Gyroids. Automotive and aerospace industry
have a growing demand for strong and light structures, which can be solved using
TPMS models. In this research we will try and understand some of the properties of
these Triply Periodic Minimal Surface (TPMS) structures and see how they perform
in comparison to the conventional models. The research was concentrated on the
mechanical, thermal and fluid flow properties of the Schwarz D, Gyroid and Spherical
Gyroid Triply Periodic Minimal Surface (TPMS) models in particular, other Triply
Periodic Minimal Surface (TPMS) models were not considered. A detailed finite
element analysis was performed on the mechanical and thermal properties using ANSYS
19.2 and the flow properties were analyzed using ANSYS Fluent under different
conditions.
ContributorsRaja, Faisal (Author) / Phelan, Patrick (Thesis advisor) / Bhate, Dhruv (Committee member) / Rykaczewski, Konrad (Committee member) / Arizona State University (Publisher)
Created2019
Description
Many industries require workers in warehouse and stockroom environments to perform frequent lifting tasks. Over time these repeated tasks can lead to excess strain on the worker's body and reduced productivity. This project seeks to develop an exoskeletal wrist fixture to be used in conjunction with a powered exoskeleton arm to aid workers performing box lifting types of tasks. Existing products aimed at improving worker comfort and productivity typically employ either fully powered exoskeleton suits or utilize minimally powered spring arms and/or fixtures. These designs either reduce stress to the user's body through powered arms and grippers operated via handheld controls which have limited functionality, or they use a more minimal setup that reduces some load, but exposes the user's hands and wrists to injury by directing support to the forearm. The design proposed here seeks to strike a balance between size, weight, and power requirements and also proposes a novel wrist exoskeleton design which minimizes stress on the user's wrists by directly interfacing with the object to be picked up. The design of the wrist exoskeleton was approached through initially selecting degrees of freedom and a ROM (range of motion) to accommodate. Feel and functionality were improved through an iterative prototyping process which yielded two primary designs. A novel "clip-in" method was proposed to allow the user to easily attach and detach from the exoskeleton. Designs utilized a contact surface intended to be used with dry fibrillary adhesives to maximize exoskeleton grip. Two final designs, which used two pivots in opposite kinematic order, were constructed and tested to determine the best kinematic layout. The best design had two prototypes created to be worn with passive test arms that attached to the user though a specially designed belt.
ContributorsGreason, Kenneth Berend (Author) / Sugar, Thomas (Thesis director) / Holgate, Matthew (Committee member) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
The goal of our research was to develop and validate a method for predicting the mechanical behavior of Additively Manufactured multi-material honeycomb structures. Multiple approaches already exist in the field for modeling the behavior of cellular materials, including the bulk property assumption, homogenization and strut level characterization [1]. With the bulk property approach, the structure is assumed to behave according to what is known about the material in its bulk formulation, without regard to its geometry or scale. With the homogenization technique, the specimen that is being tested is treated as a solid material within the simulation environment even if the physical specimen is not. Then, reduced mechanical properties are assigned to the specimen to account for any voids that exist within the physical specimen. This approach to mechanical behavior prediction in cellular materials is shape dependent. In other words, the same model cannot be used from one specimen to the next if the cell shapes of those lattices differ in any way. When using the strut level characterization approach, a single strut (the connecting member between nodes constituting a cellular material) is isolated and tested. With this approach, there tends to be a significant deviation in the experimental data due to the small size of the isolated struts. Yet it has the advantage of not being shape sensitive, at least in principle. The method that we developed, and chose to test lies within the latter category, and is what we have coined as the Representative Lattice Element (RLE) Method. This method is modeled after the well-established Representative Volume Element (RVE) method [2]. We define the RLE as the smallest unit over which mechanical tests can be conducted that will provide results which are representative of the larger lattice structure. In other words, the theory is that a single member (or beam in this case) of a honeycomb structure can be taken, tests can be conducted on this member to determine the mechanical properties of the representative lattice element and the results will be representative of the mechanical behavior whole structure. To investigate this theory, we designed specimens, conducted various tensile and compression tests, analyzed the recorded data, conducted a micromechanics study, and performed structural simulation work using commercial Finite Element Analysis software.
ContributorsSalti, Ziyad Zuheir (Co-author) / Eppley, Trevor (Co-author) / Bhate, Dhruv (Thesis director) / Song, Kenan (Committee member) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2018-05
Description
The purpose of the project is to study how the mechanical properties of cellular structures made by Fused Deposition Modeling (FDM) change depending on the number of unit cells and the cell geometry. Specimens with three geometries of regular hexagon, square, and equilateral triangle were produced by FDM. The number of cells was varied systematically in each of the three geometries. The samples were tested for compressive strength. The specimens were laser-scanned to determine the actual dimensions, and those values were used in calculations to reduce the dimensional errors. Based on the calculations and analysis, it was concluded that for each geometry, the material modulus converged to a limiting value as the number of unit cells approached "infinity", and the convergent values of the material modulus were approximately the same (within 10% of error) for the three geometries. The convergent values for the material modulus of the hexagon, square, and triangle geometries were 273ksi, 248ksi, and 262ksi respectively. The percentages of error of the square and triangle geometries with respect to the hexagon geometry were 4.0%, and 9.2%, respectively.
ContributorsLe, Thao Nguyen Minh (Author) / Parsey, John (Thesis director) / Bhate, Dhruv (Committee member) / School of Mathematical and Statistical Sciences (Contributor) / Engineering Programs (Contributor) / Barrett, The Honors College (Contributor)
Created2016-12
Description
While many 3D printed structures are rigid and stationary, the potential for complex geometries offers a chance for creative and useful motion. Printing structures larger than the print bed, reducing the need for support materials, maintaining multiple states without actuation, and mimicking origami folding are some of the opportunities offered by 3D printed hinges. Current efforts frequently employ advanced materials and equipment that are not available to all users. The purpose of this project was to develop a parametric, print-in-place, self-locking hinge that could be printed using very basic materials and equipment. Six main designs were developed, printed, and tested for their strength in maintaining a locked position. Two general design types were used: 1) sliding hinges and 2) removable pin hinges. The test results were analyzed to identify and explain the causes of observed trends. The amount of interference between the pin vertex and knuckle hole edge was identified as the main factor in hinge strength. After initial testing, the designs were modified and applied to several structures, with successful results for a collapsible hexagon and a folding table. While the initial goal was to have one CAD model as a final product, the need to evaluate tradeoffs depending on the exact application made this impossible. Instead, a set of design guidelines was created to help users make strategic decisions and create their own design. Future work could explore additional scaling effects, printing factors, or other design types.
ContributorsAndreotti, Jaimee Jeannette (Author) / Bhate, Dhruv (Thesis director) / Aukes, Daniel (Committee member) / Dean, W.P. Carey School of Business (Contributor) / Mechanical and Aerospace Engineering Program (Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
Description
Due to the vast increase in processing power and energy usage in computing, a need for greater heat dissipation is prevalent. With numerous applications demanding cheaper and more efficient options for thermal management, new technology must be employed. Through the use of additive manufacturing, designs and structures can be created that were not physically possible before without extensive costs. The goal is to design a system that utilizes capillary action, which is the ability for liquids to flow through narrow spaces unassisted. The level of detail required may be achieved with direct metal laser sintering (DMLS) and stereolithography (SLA) 3D printing.
ContributorsFechter, Andrew (Author) / Bhate, Dhruv (Thesis director) / Frank, Daniel (Committee member) / Engineering Programs (Contributor, Contributor) / Barrett, The Honors College (Contributor)
Created2021-05
Description
Applications such as heat exchangers, surface-based cellular structures, rotating blades, and waveguides rely on thin metal walls as crucial constituent elements of the structure. The design freedom enabled by laser powder bed fusion has led to an interest in exploiting this technology to further the performance of these components, many of which retain their as-built surface morphologies on account of their design complexity. However, there is limited understanding of how and why mechanical properties vary by wall thickness for specimens that are additively manufactured and maintain an as-printed surface finish. Critically, the contributions of microstructure and morphology to the mechanical behavior of thin wall laser powder bed fusion structures have yet to be systematically identified and decoupled. This work focuses on elucidating the room temperature quasi-static tensile and high cycle fatigue properties of as-printed, thin-wall Inconel 718 fabricated using laser powder bed fusion, with the aim of addressing this critical gap in the literature. Wall thicknesses studied range from 0.3 - 2.0 mm, and the effects of Hot Isostatic Pressing are also examined, with sheet metal specimens used as a baseline for comparison. Statistical analyses are conducted to identify the significance of the dependence of properties on wall thickness and Hot Isostatic Pressing, as well as to examine correlations of these properties to section area, porosity, and surface roughness. A thorough microstructural study is complemented with a first-of-its-kind study of surface morphology to decouple their contributions and identify underlying causes for observed changes in mechanical properties. This thesis finds that mechanical properties in the quasi-static and fatigue framework do not see appreciable declines until specimen thickness is under 0.75 mm in thickness. The added Hot Isostatic Pressing heat treatment effectively closed pores, recrystallized the grain structure, and provided a more homogenous microstructure that benefits the modulus, tensile strength, elongation, and fatigue performance at higher stresses. Stress heterogeneities, primarily caused by surface defects, negatively affected the thinner specimens disproportionately. Without the use of the Hot Isostatic Pressing, the grain structure remained much more refined and benefitted the yield strength and fatigue endurance limit.
ContributorsParadise, Paul David (Author) / Bhate, Dhruv (Thesis advisor) / Chawla, Nikhilesh (Committee member) / Azeredo, Bruno (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2022
Description
The study aims to develop and evaluate failure prediction models that accurately predict crack initiation sites, fatigue life in additively manufactured Ti-6Al-4V, and burst pressure in relevant applications.The first part proposes a classification model to identify crack initiation sites in AM-built Ti-6Al-4V alloy. The model utilizes surface and pore-related parameters and achieves high accuracy (0.97) and robustness (F1 score of 0.98). Leveraging CT images for characterization and data extraction from the CT-images built STL files, the model effectively detects crack initiation sites while minimizing false positives and negatives. Data augmentation techniques, including SMOTE+Tomek Links, are employed to address imbalanced data distributions and improve model performance.
This study proposes the Probabilistic Physics-guided Neural Network 2.0 (PPgNN) for probabilistic fatigue life estimation. The presented approach overcomes the limitations of classical regression machine models commonly used to analyze fatigue data. One key advantage of the proposed method is incorporating known physics constraints, resulting in accurate and physically consistent predictions.
The efficacy of the model is demonstrated by training the model with multiple fatigue S-N curve data sets from open literature with relevant morphological data and tested using the data extracted from CT-built STL files. The results illustrate that PPgNN 2.0 is a flexible and robust model for predicting fatigue life and quantifying uncertainties by estimating the mean and standard deviation of the fatigue life. The loss function that trains the proposed model can capture the underlying distribution and reduce the prediction error.
A comparison study between the performance of neural network models highlights the benefits of physics-guided learning for fatigue data analysis. The proposed model demonstrates satisfactory learning capacity and generalization, providing accurate fatigue life predictions to unseen examples.
An elastic-plastic Finite Element Model (FEM) is developed in the second part to assess pipeline integrity, focusing on burst pressure estimation in high-pressure gas pipelines with interactive corrosion defects. The FEM accurately predicts burst pressure and evaluates the remaining useful life by considering the interaction between corrosion defects and neighboring pits. The FEM outperforms the well-known ASME-B31G method in handling interactive corrosion threats.
ContributorsBalamurugan, Rakesh (Author) / Liu, Yongming (Thesis advisor) / Zhuang, Houlong (Committee member) / Bhate, Dhruv (Committee member) / Arizona State University (Publisher)
Created2023
Description
The conversion of H2S enables the recycling of a waste gas into a potential source of hydrogen at a lower thermodynamic energy cost as compared to water splitting. However, studies on the photocatalytic decomposition of H2S focus on traditional deployment of catalyst materials to facilitate this conversion, and operation only when a light source is available. In this study, the efficacy of Direct Ink Written (DIW) luminous structures for H2S conversion has been investigated, with the primary objective of sustaining H2S conversion when a light source has been terminated. Additionally, as a secondary objective, improving light distribution within monoliths for photocatalytic applications is desired. The intrinsic illumination of the 3D printed monoliths developed in this work could serve as an alternative to monolith systems that employ light transmitting fiber optic cables that have been previously proposed to improve light distribution in photocatalytic systems. The results that were obtained demonstrate that H2S favorable adsorbents, a wavelength compatible long afterglow phosphor, and a photocatalyst can form viscoelastic inks that are printable into DIW luminous monolithic contactors. Additionally, rheological, optical and porosity analyses conducted, provide design guidelines for future studies seeking to develop DIW luminous monoliths from compatible catalyst-phosphor pairs. The monoliths that were developed demonstrate not only improved conversion when exposed to light, but more significantly, extended H2S conversion from the afterglow of the monoliths when an external light source was removed. Lastly, considering growing interests in attaining a global circular economy, the techno-economic feasibility of a H2S-CO2 co-utilization plant leveraging hydrogen from H2S photocatalysis as a feed source for a downstream CO2 methanation plant has been assessed. The work provides preliminary information to guide future chemical kinetic design characteristics that are important to strive for if using H2S as a source of hydrogen in a CO2 methanation facility.
ContributorsAbdullahi, Adnan (Author) / Andino, Jean (Thesis advisor) / Phelan, Patrick (Thesis advisor) / Bhate, Dhruv (Committee member) / Wang, Robert (Committee member) / Huang, Huei-Ping (Committee member) / Arizona State University (Publisher)
Created2023
Description
One of the fundamental aspects of cellular material design is cell shape selection. Of particular interest is how this selection can be made in the context of a realistic three-dimensional structure. Towards this goal, this work studied the stiffness response of periodic and stochastic lattice structures for the loading conditions of bending, torsion and tension/compression using commercially available lattice design optimization software. The goal of this computational study was to examine the feasibility of developing a ranking order based on minimum compliance or maximum stiffness for enabling cell selection. A study of stochastic shapes with different seeds was also performed. Experimental compression testing was also performed to validate a sample space of the simulations. The findings of this study suggest that under certain circumstances, stochastic shapes have the potential to generate the highest stiffness-to-weight ratio in the test environments considered.
ContributorsSharma, Raghav (Author) / Bhate, Dhruv (Thesis advisor) / Oswald, Jay (Committee member) / Kwon, Beomjin (Committee member) / Arizona State University (Publisher)
Created2019