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Effect of pore architecture of 3D printed open porosity cellular structures on their resistance to mechanical loading. Part I, Experimental studies

Bernacka Monika, Aladag Mehmet, Dubicki Adrian, Zgłobicka Izabela

Acta Mechanica et Automatica

2024

Vol. 18, no. 3

419--426

The development of additive manufacturing (AM) techniques has sparked interest in porous structures that can be customized in terms of size, shape, and arrangement of pores. Porous lattice structure (LS, called also lattice struct) offer superior specific stiffness and strength, making them ideal components for lightweight products with energy absorption and heat transfer capabilities. They find applications in industries such as aerospace, aeronautics, automotive, and bone ingrowth applications. One of the main advantages of additive manufacturing is the freedom of design, control over geometry and architecture, cost and time savings, waste reduction, and product customization. However, the designation of appropriate struct/pore geometry to achieve the desired properties and structure remains a challenge. In this part of the study, five lattice structs with various pore sizes, with two volume fractions for each, and shapes (ellipsoidal, helical, X-shape, trapezoidal, and triangular) were designed and manufactured using selective laser sintering (SLS) additive manufacturing technology. Mechanical properties were tested through uniaxial compression, and the apparent stress-strain curves were analyzed. The results showed that the compression tests revealed both monotonic and non-monotonic stress-strain curves, indicating different compression behaviors among the structures. The helical structure exhibited the highest resistance to compression, while other structures showed similarities in their mechanical properties. In Part II of this study provides a comprehensive analysis of these findings, emphasizing the potential of purpose-designed porous structures for various engineering applications.

Reverse engineering of parts with asymmetrical properties using replacement materials

Aladag Mehmet, Bernacka Monika, Joka-Yildiz Magdalena, Grodzki Wojciech, Zamojski Przemysław, Zgłobicka Izabela

Acta Mechanica et Automatica

2022

Vol. 16, no. 3

250--258

Reverse engineering (RE) aims at the reproduction of products following a detailed examination of their construction or composition. Nowadays, industrial applications of RE were boosted by combining it with additive manufacturing. Printing of reverse-engineered elements has become an option particularly when spare parts are needed. In this paper, a case study was presented that explains how such an approach can be implemented in the case of products with asymmetric mechanical properties and using replacement materials. In this case study, a reverse engineering application was conducted on a textile machine spare part. To this end, the nearest material was selected to the actual material selection and some mechanical tests were made to validate it. Next, a replacement part was designed by following the asymmetric push-in pull-out characteristic. Finally, the finite element analysis with Additive Manufacturing was combined and validated experimentally.