- Award ID(s):
- Publication Date:
- NSF-PAR ID:
- Journal Name:
- Journal of Manufacturing Science and Engineering
- Page Range or eLocation-ID:
- 1 to 30
- Sponsoring Org:
- National Science Foundation
More Like this
On numerical modeling of equal channel angular extrusion of ultra high molecular weight polyethyleneUltra high molecular weight polyethylene (UHMWPE) is widely used in biomedical applications, e.g. as a bearing surface in total joint arthroplasty. Recently, equal channel angular extrusion (ECAE) was proposed as a processing method to achieve higher molec ular entanglement and superior mechanical properties of this material. Numerical modeling can be utilized to evaluate the influence of such important manufacturing parameters as the extrusion rate, temperature, geometry of the die, back pressure and fricti on effects in the ECAE of polyethylenes. In this paper we focus on the development of efficient FE models of ECAE for UHMWPE. We study the applicability of the available constitutive models traditionally used in polymer mechanics for UHMWPE, evaluate the importance of the proper choice of the friction parameters between the billet and the die, and compare the accuracy of predictions between 2D (plane strain) and 3D models. Our studies demonstrate that the choice of the constitutive model is extremely important for the accuracy of numerical modeling predictions. It is also shown that the friction coefficient significantly influences the punch force and that 2D plane strain assumption can become inaccurate in the presence of friction between the billet and the extrusion channel.
Deep neural operator for learning transient response of interpenetrating phase composites subject to dynamic loadingAdditive manufacturing has been recognized as an industrial technological revolution for manufacturing, which allows fabrication of materials with complex three-dimensional (3D) structures directly from computer-aided design models. Using two or more constituent materials with different physical and mechanical properties, it becomes possible to construct interpenetrating phase composites (IPCs) with 3D interconnected structures to provide superior mechanical properties as compared to the conventional reinforced composites with discrete particles or fibers. The mechanical properties of IPCs, especially response to dynamic loading, highly depend on their 3D structures. In general, for each specified structural design, it could take hours or days to perform either finite element analysis (FEA) or experiments to test the mechanical response of IPCs to a given dynamic load. To accelerate the physics-based prediction of mechanical properties of IPCs for various structural designs, we employ a deep neural operator (DNO) to learn the transient response of IPCs under dynamic loading as surrogate of physics-based FEA models. We consider a 3D IPC beam formed by two metals with a ratio of Young’s modulus of 2.7, wherein random blocks of constituent materials are used to demonstrate the generality and robustness of the DNO model. To obtain FEA results of IPC properties, 5000more »
Shear enhancement of mechanical and microstructural properties of synthetic graphite and ultra‐high molecular weight polyethylene carbon composites
Ultra‐high molecular weight polyethylene (UHMWPE) has a variety of industrial and clinical applications due to its superb mechanical properties including ductility, tensile strength, and work‐to‐failure. The versatility of UHMWPE is hindered by the difficulty in processing the polymer into a well consolidated material. This study presents on the effects of shear imparted by equal channel angular pressing (ECAP) on UHMWPE composites containing Nano27 Synthetic Graphite (N27SG). Ductility and work‐to‐failure improvements up to ~60–80% are obtained in sheared N27SG‐UHMWPE composites as compared to non‐sheared N27SG‐UHMWPE controls of the same composition. Microscopy reveals increased fusion at particle boundaries and smaller voids in the sheared materials. Micro‐computed tomography results indicate different distribution of N27SG particulates in ECAP samples as compared to CM indicating enhanced grain boundary interactions. Tradeoffs are not avoided as ECAP samples were lower in conductivity as compared to compression molded (CM) billets of the same weight percent. However, ECAP samples were able to be doped with more N27SG allowing for an ~170% increase in conductivity over CM samples of the same work‐to‐failure. This work shows that ECAP is a viable processing method for obtaining stronger, more ductile conductive composite materials.
Modeling Fretting Wear Resistance and Shakedown of Metallic Materials with Graded Nanostructured SurfacesIn applications involving fretting wear damage, surfaces with high yield strength and wear resistance are required. In this study, the mechanical responses of materials with graded nanostructured surfaces during fretting sliding are investigated and compared to homogeneous materials through a systematic computational study. A three-dimensional finite element model is developed to characterize the fretting sliding characteristics and shakedown behavior with varying degrees of contact friction and gradient layer thicknesses. Results obtained using a representative model material (i.e., 304 stainless steel) demonstrate that metallic materials with a graded nanostructured surface could exhibit a more than 80% reduction in plastically deformed surface areas and volumes, resulting in superior fretting damage resistance in comparison to homogeneous coarse-grained metals. In particular, a graded nanostructured material can exhibit elastic or plastic shakedown, depending on the contact friction coefficient. Optimal fretting resistance can be achieved for the graded nanostructured material by decreasing the friction coefficient (e.g., from 0.6 to 0.4 in 304 stainless steel), resulting in an elastic shakedown behavior, where the plastically deformed volume and area exhibit zero increment in the accumulated plastic strain during further sliding. These findings in the graded nanostructured materials using 304 stainless steel as a model system can be furthermore »
Effects of infill patterns on the strength and stiffness of 3D printed topologically optimized geometriesPurpose Mechanical anisotropy associated with material extrusion additive manufacturing (AM) complicates the design of complex structures. This study aims to focus on investigating the effects of design choices offered by material extrusion AM – namely, the choice of infill pattern – on the structural performance and optimality of a given optimized topology. Elucidation of these effects provides evidence that using design tools that incorporate anisotropic behavior is necessary for designing truly optimal structures for manufacturing via AM. Design/methodology/approach A benchmark topology optimization (TO) problem was solved for compliance minimization of a thick beam in three-point bending and the resulting geometry was printed using fused filament fabrication. The optimized geometry was printed using a variety of infill patterns and the strength, stiffness and failure behavior were analyzed and compared. The bending tests were accompanied by corresponding elastic finite element analyzes (FEA) in ABAQUS. The FEA used the material properties obtained during tensile and shear testing to define orthotropic composite plies and simulate individual printed layers in the physical specimens. Findings Experiments showed that stiffness varied by as much as 22% and failure load varied by as much as 426% between structures printed with different infill patterns. The observed failure modes weremore »