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A comprehensive design framework for additive manufacturing in the automotive industry: a case study

Lkadi O., Abouhazim S., Nassraoui M., Bouksour O.

Archives of Materials Science and Engineering

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2024

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Vol. 125, nr 1

32--41

EN

Purpose: The work aims to propose a comprehensive design framework for additive manufacturing and apply it to a case study of the height adjuster handle of a car. The aim is to provide designers and engineers with a practical example of how the framework can be used to design a complex part for additive manufacturing. The article also aims to demonstrate the potential benefits of additive manufacturing in the automotive industry, such as improved performance, reduced times, and cost savings. Additionally, the article aims to compare the developed framework with existing design for additive manufacturing (DFAM) methodologies and highlight its unique features and advantages in designing the height adjuster handle. Design/methodology/approach: The study used qualitative and quantitative data collection and analysis methods. The first phase of the study involved a systematic review of existing DfAM methodologies and a critical analysis of their strengths and weaknesses. Based on this analysis, a new DfAM framework is developed, which aims to address the limitations of existing frameworks and provide a comprehensive design approach for additive manufacturing. The second phase of the study involved applying the developed framework to a case study of a complex automotive part - a height adjuster handle. The design requirements of the height adjuster handle were identified based on the principles of DfAM, and the part was designed using computer-aided design (CAD) software and optimised topologically using ANSYS software. In the third phase, the performance of the height adjuster handle designed using the developed framework was compared with a part manufactured with injection moulding technology. The comparison was based on various performance criteria, including mechanical properties, dimensional accuracy, and production time and cost. Findings: The findings of the study demonstrate the effectiveness of the developed design framework for additive manufacturing (DfAM) in producing a complex automotive part with improved performance characteristics and reduced lead time. Research limitations/implications: Although the results of the study provide important insights into the effectiveness of the developed DfAM framework for producing a complex automotive part, there are some limitations to the research that should be considered, such as the case study involved the design of a single part, and the results may not be generalisable to other parts or applications. Further research is needed to validate the effectiveness of the DfAM framework for a broader range of automotive parts. for the automotive industry. The developed DfAM framework can be used in the FDM technology. It can be used as a decision aid in the manufacturing of FDM parts in order to improve the efficiency and cost-effectiveness of the production process for complex automotive parts. Originality/value: The value of the study is the development of a novel DfAM framework and the demonstration of its effectiveness in a case study. The proposed framework can be used as a reference for future research. It can also provide practical guidance for industry professionals seeking to improve the efficiency and cost-effectiveness of their additive manufacturing processes.

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Experimental investigation of mechanical stiffness in lattice structures fabricated with PLA using fused deposition modelling

Eljihad A., Nassraoui M., Bouksou O.

Journal of Achievements in Materials and Manufacturing Engineering

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2023

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Vol. 119, nr 2

60--71

EN

Purpose: The objective of the paper is to design and characterise with polylactic acid (PLA) material three cellular structures in the form of lattices which are diagonal-octet-centred shapes for two sizes 6x6x6 and 12x12x12 with a compression test to examine their stiffness using FDM technology compared to polyjet technology. Design/methodology/approach: The study used two analytical approaches to investigate lattice structures: experimental analysis and theoretical analysis. Experimental methods such as compression tests were conducted to determine the characteristics of lattice structures. In addition, theoretical analysis was conducted using Hook's law and Ashby's Gibson model to predict appropriate behaviour. The combination of experimental and theoretical methods provided a comprehensive understanding of lattice structures and their properties. Findings: The experimental study examined the impact of the shape and size of a lattice structure on the stiffness and lightness of objects 3D printed with FDM technology by PLA material. The research revealed that the 6x6x6 diagonal lattice structure size provided a good balance between stiffness and lightness. While the 6x6x6 byte structure was even lighter, with a mass ratio of 2.09 compared to the diagonal structure, it was less rigid, with a ratio of 0.43, making the diagonal structure more suitable for certain applications. The study highlights the importance of considering both the shape and size of the lattice structure when designing 3D-printed objects with specific mechanical properties; the chosen structure could be a good choice for applications where stiffness and lightness are important. Research limitations/implications: The limitations of the research lie in its limited scope, focusing primarily on the effect of shape (octet-diagonal centred) and unit cell size on Young's modulus of PLA material. Other aspects of 3D printing, such as material selection and thermal properties, were not considered. Furthermore, the results obtained are specific to the printing parameters and experimental conditions chosen, which limits their generalizability to other 3D printing configurations or methods. However, these results have important implications for optimising the PLA printing process. They enable the identification of optimal parameters, such as unit cell shape and size, to produce stiffer, higher-quality structures. In addition, the research is helping to improve the mechanical properties of 3D-printed lattice parts, paving the way for more efficient manufacturing methods and stronger components. Practical implications: Our analysis can be used as a decision aid for the design of FDM lattice parts. Indeed, we can choose the diagonal structure of 6x6x6, which would provide favourable stiffness for functional parts. Originality/value: The paper explores the compression test of lattice structures using FDM technology, which presents a new direction for additive manufacturing. The study takes an experimental approach to evaluate the reliability of various additive manufacturing technologies for creating lattice structures. The study results provide insight into the most reliable technology for producing lattice structures.

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Numerical investigation of the effect of topology optimisation methods parameters in the topology quality, the strength, and the computational cost

Ait Ouchaoui A., Nassraoui M., Radi B.

Archives of Materials Science and Engineering

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2023

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Vol. 123, nr 2

55--71

EN

Purpose: The literature abounds with many distinct topology optimisation methods, many of which share common parameter configurations. This study demonstrates that alternative parameter configurations may produce better results than common parameters. Additionally, we try to answer two fundamental questions: identifying the most effective topology optimisation method and determining the optimal parameter selection within this optimisation method. In order to respond to these questions, we conducted a comparative and objective analysis of topology optimisation methods. Design/methodology/approach: This paper evaluates four prominent topology optimisation methodologies, SIMP, RAMP, BESO, and LSM, based on three essential criteria: structural strength, topology quality, and computational cost. We conducted an in-depth examination of 12,500 topology optimisation results spanning a broad range of critical parameter values. These outcomes were generated using MATLAB codes. In the meantime, we comprehensively compared our findings with the existing literature on this subject. Findings: As predicted, our chosen parameters had a substantial effect on the topology quality, structural strength, and computational cost of the topology optimisation outcomes. Across the 12,500 results, many parameter combinations appeared to produce favourable results compared to conventional parameters commonly found in the existing literature. Research limitations/implications: This study focuses exclusively on four specific topology optimisation methods; however, its findings may be extrapolated to apply to other methodologies. Additionally, while it extensively examines the effects of parameters on topology quality, strength, and computational cost, it does not encompass an exploration of these parameters' impacts on other performance criteria. Originality/value: Novel parameter configurations for topology optimisation have been identified, yielding enhanced outcomes in terms of topology quality, structural strength, and computational efficiency.