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Title: Rapid
fabrication of metal-coated composite stereolithography parts
Author(s): Z Zhou, D Li, J Zeng, Z Zhang
Source: Proceedings of the I MECH E Part B Journal of Engineering
Manufacture
Volume: 221, No 9. September 2007
DOI: 10.1243/09544054JEM827
Pages: 1431-1440
Publisher: Professional Engineering Publishing
Abstract: In this paper, the rapid fabrication method based
on stereolithography (SL) and electrochemical deposition is described
in detail and mechanical test results of composite nickel-coated
SL parts are presented. Coatings of electrodeposited nickel on SL
prototypes result in increases in Young's modulus, UTS, flexural
modulus, and strength. Electrodeposited nickel coating has dramatically
improved the overall strength and stiffness of SL parts. The adhesive
strength of the roughened SL resin-nickel interface is higher than
the original. In particular, the influence of the surface roughness
on adhesive strength between SL and metal is investigated. Moreover,
this paper has presented an application of a structural electrodeposited
nickel coating over SL parts to make a functional airfoil model
with a complex internal structure and sufficient mechanical strength
and stiffness.
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Title: Cost
forecasting model for order-based sheet metalworking
Author(s): A Bargelis, M Rimasauskas
Source: Proceedings of the I MECH E Part C Journal of Mechanical
Engineering Science
Volume: 221 Page: 55-65 - 211. January 2007
DOI: 10.1243/0954406JMES269
Publisher: Professional Engineering Publishing
Abstract: This paper deals with a cost forecasting model
for order-based sheet metalworking. The model has been developed
on the cost analysis performed by comparing traditional manufacture
of sheet metal parts (dies and presses) with rapid manufacture (RM)
as CNC punching, laser cutting, and bending in terms of the cost
per part unit made in various quantities. The findings show that
it is more economical to apply RM methods for some sheet metal design
geometries than traditional approaches in the production of thousand
units. The developed cost forecasting model has been tested and
adopted in two sheet metalworking companies. It furnishes the possibility
for producer to find quickly and to estimate the product cost at
an early stage of order-based sheet metalworking industry with satisfactory
accuracy. The proposed model is being implemented both in industry
and university education process.
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Title: Design
for environment analyses applied to rapid manufacturing
Author(s): N Hopkinson, Y Gao, D J McAfee
Source: Proceedings of the I MECH E Part D Journal
of Automobile Engineering
Volume: 220 Page: 1363-1372. Oct 2006
DOI: 10.1243/09544070JAUTO309
Publisher: Professional Engineering Publishing
Abstract: This paper explores the potential to
combine rapid manufacturing (RM) technologies and design for environment
(DFE) software with an automotive application. The work focuses
on the redesign of a door handle assembly for the Jaguar XJ Saloon.
The original 11-piece assembly, comprising eight different materials,
was subject to a redesign with an RM technology in mind as the method
for final manufacture. In this case the suggested method for manufacture
was selective laser sintering (SLS). The design freedoms afforded
by the SLS process had a profound effect on the potential to redesign
the product. Two different redesigns were proposed, and these, along
with the original design, were subjected to analyses of environmental
burden and financial profits/costs for end-of-life recycling and
reuse using Boothroyd Dewhurst DFE software. The first redesign
incorporated the entire assembly as a single prefabricated unit
and consequently rendered a DFE analysis impossible. The second
redesign was a four-piece assembly retaining three metallic components
from the original product and, when subjected to the DFE analysis,
showed a significant reduction in environmental burden and cost
for disassembly. The surface finish of the SLS parts proved to be
inadequate for visual components on a luxury car, but the potential
to apply RM for applications with less stringent aesthetic requirements
remains.
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Title: A
procedure for the virtual evaluation of the stress state of mechanical
systems and components for the automotive industry: development
and experimental validation
Author(s): C Braccesi; F Cianetti
Source: Proceedings of the I MECH E Part D Journal
of Automobile Engineering
Volume: 219 Page: 633 - 643. May 2005
DOI: 10.1243/095440705X11040
Publisher: Professional Engineering Publishing
Abstract: This paper is part of the research activity
led by the Machine Design Group of the University of Perugia, whose
main objective was to set up and develop modelling criteria and
methods for dynamic simulation of mechanical systems including flexible
components. The activity was finalized to the design of systems
using virtual prototyping, driving the modelling accuracy to simulate
real functioning conditions of the system. It was therefore possible
to extract realistic and directly usable information for fatigue
component design using any fatigue damage evaluation criterion.
In particular, the present work was developed with the cooperation
of the research centre Elasis S.C.p.a. and concerns the set-up of
methods and criteria for the development of the virtual prototype
of an auto-vehicle, with the aim of simulating the conditions of
sign-off tests. This aspect of virtual prototyping has a relevant
importance. The sign-off tests of the vehicle, in fact, are standardized
and the results obtained constitute one of the main sources of information
for product development using physical prototypes. The industry
is interested in reducing, as much as possible, the tests on prototypes
by developing predictive virtual prototyping methods.
The results obtained in this paper show an optimum correspondence
between numerical and experimental simulations and demonstrate that
time-domain stress/strain numerical recovery in critical points
of the chassis is not only feasible but leads to quantitative information
directly usable by fatigue damage evaluation methods.
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Title: Target-identical
rapid control prototyping platform for model-based engine control
Author(s): Wootaik Lee; Minsuk Shin; Myoungho Sunwoo
Source: Proceedings of the I MECH E Part D Journal
of Automobile Engineering
Volume: 218 Page: 755 - 765. July 2004
DOI: 10.1243/0954407041580049
Publisher: Professional Engineering Publishing
Abstract: Rapid control prototyping (RCP) is one
of the most important technologies for speeding up the development
process of the electronic control unit (ECU) used in the automotive
control system. However, one big drawback of the conventional RCP
platform is the transfer from RCP to target ECU implementation.
In this study, a new RCP platform is proposed that provides a consistent
environment for both the RCP development stage and the target ECU
implementation stage. In order to make the rapid prototyping controller
as similar to a production ECU as possible, the prototyping system
follows the strictly layered architecture of the production ECU
and separates the automatically generated code of software from
the hand code. Finally, the feasibility of the developed target-identical
RCP platform is evaluated through an air-to-fuel ratio (AFR) control
application.
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