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Experimental investigation of stereolithography and digital light processing additive manufactured pallets

Bairapudi Anil, Sastry C. Chandrasekhara, Krishnaiah J., Sundeep Dola, Eswaramoorthy KV

Materials Science Poland

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2024

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Vol. 42, No. 1

1--31

EN

Pallets are a tertiary form of packaging used for stacking, storing, protecting, or transporting goods in supply chains. They are utilized as a base for the unitization of goods for logistics and warehousing. Moreover, pallets can be manufactured using wood, plastic, metal, and corrugated paper, which can be used as material-handling equipment. With several products being transported worldwide and with year-on-year growth, it would be beneficial to make lightweight pallets. Such pallets are recyclable, easy to clean, cheap, and durable to maintain and store. Though most of the pallets are widely available for basic purposes, applications involving high-end bio-packings and transportation of special chemicals require specialized pallets to be manufactured like polymers to ensure a negligible chemical reaction, light in weight, and attenuation in freight capacity, thereby widespread reduction in wastage. With advancements, job to job and immediate requirements, additive manufacturing has the potential to close the gap for jobs with short lead times. If the design process of new pallets has limits the creation of specific codes, the transitions will be smoother in rapid prototyping. This work describes the development of polymer pallets by taking advantage of stereolithography (SLA) and digital light processing (DLP) technology for 3D printing pallets in correlation to injection moulding. After the pallets are designed and manufactured, AM technologies can be applied to specified standards, and the pallets then undergo tensile strength, elongation, and hardness tests. The analysis was carried out for configurable geometries adapting to fork lifting, conveyor, racking, and stacking conditions. Analytical and numerical solutions were carried out to understand the stress and deflections for each geometry and its wide range of applications for pallets.

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Investigation of additive manufactured micro-lattice structures for defence applications

Shaik Ameer Malik, Reddy Bobbili Veera Siva, Sastry C. Chandrasekhara, Krishnaiah J., Ramakrishna B.

Materials Science Poland

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2023

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Vol. 41, No. 2

383--400

EN

This study investigates the blast mitigation capabilities of A286 steel micro-lattice structures produced through additive manufacturing. The research explores the effects of different manufacturing conditions, such as stress relief and heat treatment, on the mechanical properties and blast resistance of honeycomb and gyroid lattice structures in correlation with armour steel structures. Comprehensive evaluations, including surface morphology, corrosion resistance, and compressive residual stress analysis, reveal notable findings for micro-lattice structures. Micro-lattice structures demonstrated 57.23% higher corrosion resistance compared to conventional materials, presently available in the form of rolled homogeneous armour, medium hardness armour, and high-nitrogen steel. Additionally, honeycomb lattice structures exhibit compressive residual stresses of up to 581.90 MPa, providing significant advantages in blast mitigation potential. These results underscore the significance of lattice geometry, material microstructure, and residual stress in enhancing blast resistance. The research offers valuable insights into optimizing additive manufactured structures as an alternative modular solution for defence applications.

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Experimental investigation of the electrochemical micromachining process of Ti-6Al-4V titanium alloy under the influence of magnetic field

Gopinath T. Praveena, Prasanna J., Sastry C. Chandrasekhara, Patil Sandeep

Materials Science Poland

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2021

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Vol. 39, No. 1

124--138

EN

An attempt has been made to study the influence of magnetic field on the micro hole machining of Ti-6Al-4V titanium alloy using electrochemical micromachining (ECMM) process. The presence of magneto hydro dynamics (MHD) is accomplished with the aid of external magnetic field (neodymium magnets) in order to improve the machining accuracy and the performance characteristics of ECMM. Close to ideal solution for magnetic and nonmagnetic field ECMM process, the parameters used are as follows: concentration electrolyte of 15 g/l; peak current of 1.35 A; pulse on time of 400 s; and duty factor of 0.5. An improvement of 11.91–52.43% and 23.51–129.68% in material removal rate (MRR) and 6.03–21.47% and 18.32–33.09% in overcut (OC) is observed in ECMM of titanium alloy under the influence of attraction and repulsion magnetic field, respectively, in correlation with nonmagnetic field ECMM process. A 55.34% surface roughness factor reduction is ascertained in the hole profile in magnetic field-ECMM in correlation with electrochemical machined titanium alloy under nonmagnetic field environment. No machining related stress is induced in the titanium alloy, even though environment of electrochemical machining process has been enhanced with the presence of magnetic field. A slight surge in the compressive residual factor, aids in surge of passivation potential of titanium alloy, resulting in higher resistance to outside environment.