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ABSTRACT
The accuracy of meso-scaled thermomechanical method (TMM) in analysing distortion of hinge bracket additively manufactured using selective laser melting (SLM) is investigated with SS316L as material and optimised design using Generative Design (GD) approach in which loads, boundaries, and constraints are considered as parametric inputs and stress goal as output. Prior to 3D printing, process simulation for predicting distortion was conducted including a geometrical model with hexahedral mesh type, temperature dependent material and flow curve referred from specialised software. To reduce computational time, a lumping approach with volume fraction was implemented considering heat flux parameters. For validation purposes, a series of experiments was accomplished using SLM, manual support structure removal, and surface finishing process by sandblasting. Furthermore, the finished bracket was measured using an optical scanner and compared with the simulation result. In conclusion, TMM can predict the distortion accurately with percentage point-by-point and mean error of less than 3% and 1.5%, respectively.
Acknowledgments
The authors would like to express their gratitude to the staff members of Smart Manufacturing Research Institute (SMRI) and Research Interest Group: Advanced Manufacturing Technology (RIG:AMT) at School of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Shah Alam as well as Professorship of Virtual Production Engineering at Chemnitz University of Technology (CUT) in Germany for encouraging this research. This research is financially supported by Fundamental Research Grant Scheme (FRGS) with Project Code: FRGS/1/2019/TK03/UiTM/03/5, Strategic Research Partnership (SRP) Grant with Project Code: 100-RMC 5/3/SRP (016/2020) and DAAD Germany (Future Technology Additive Manufacturing) with Project Code: 57525437.
Disclosure statement
No potential conflict of interest was reported by the author(s).
Additional information
Notes on contributors
Thoufeili Taufek
Thoufeili Taufek is currently a PhD student in the School of Mechanical Engineering at Universiti Teknologi MARA (UiTM), Shah Alam, Malaysia. His research activities are mainly focused on simulation and experiment of metal additive manufacturing and generative design.
Yupiter H. P. Manurung
Yupiter H. P. Manurung is a Full Professor in the School of Mechanical Engineering and Director of SMRI at Universiti Teknologi MARA (UiTM), Shah Alam, Malaysia. His research activities are mainly focused on virtual manufacturing, metal additive manufacturing, generative design, welding technology and artificial neural network.
Syidatul Akma
Syidatul Akma is currently a Senior Lecturer in the College of Engineering (Mechanical) at Universiti Tekenologi MARA (UiTM), Pasir Gudang, Malaysia. Her research activities are mainly focused on quality improvement in additive manufacturing using non-linear FEM.
Wan Emri Wan Abdul Rahaman
Wan Emri Wan Abdul Rahaman is currently a Senior Lecturer in the School of Mechanical Engineering at Universiti Teknologi MARA (UiTM), Shah Alam, Malaysia. His research activities are mainly focused on advanced manufacturing process and quality and reliability engineering.
Mohd Halim Irwan
Mohd Halim Irwan is currently an Associate Professor in the Faculty of Mechanical Engineering at Universiti Tun Hussein Onn Malaysia (UTHM), Batu Pahat, Malaysia. His research activities are mainly focused applied sciences and technologies, process technology and material processing technology.
Noor Azlina Mohd Salleh
Noor Azlina Mohd Salleh is currently a Senior Lecturer in the School of Mechanical Engineering at Universiti Teknologi MARA (UiTM), Shah Alam, Malaysia. Her research activities are mainly focused on lean manufacturing, productivity and quality improvement through industrial 4.0 enabling technologies applications.
Mohd Shahriman Adenan
Mohd Shahriman Adenan is currently a Senior Lecturer at the Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM), Shah Alam, Malaysia. His research activities are mainly focused on metal additive manufacturing, generative design and design.
Mohamad Madani Sahari
Mohamad Madani Sahari was Chief Executive Officer at Malaysia Automotive, Robotics & IoT Institute (MARii) in Malaysia. His expertise is mainly focused on business planning, engineering, strategic planning, business development, and marketing strategy.
Baohua Chang
Baohua Chang is currently an Associate Professor at Tsinghua University, Beijing, China. His research activities are mainly focused on modelling and simulation of welding process, welding mechanics, structural integrity assessment, advanced materials joining process, laser welding, laser additive manufacturing, weld-bonding, micro-resistance spot welding and wire bonding.
Birgit Awiszus
Birgit Awiszus is a Full Professor at Chemnitz University of Technology in Germany. Her research activities are mainly focused on forming technology and virtual manufacturing.