Additive Manufacturing
Additive Manufacturing:
Since 1980 Additive Manufacturing (AM) technology has evolved to become an alternative manufacturing technique for industry. Much of its progress has been done since 2010. However, metal AM processes still require optimized process parameters for a specific design. Generalizing the optimization parameters for most of the parts will help to save money and time. Understanding the failure mechanisms derived from process parameters are also critical. My interest is to understand these process variables behavior and suggest the optimum parameters.
BINDER JETTING ADDITIVE MANUFACTURING PROCESS
References:
R. Onler, A. S. Koca, B. Kirim, E. Soylemez, “Multi-objective optimization of binder jet additive manufacturing of Co-Cr-Mo using machine learning,” The International Journal of Advanced Manufacturing Technology , 119.1, 1091-1108, 2021 https://doi.org/10.1007/s00170-021-08183-z
References:
C. Diego, MSc Thesis, Powder bed based additive manufacturing of pure Cu with laser melting and binder jetting, Politecnico Milano, 2022
SS316L BINDER JETTING
Study was conducted to understand the geometric accuracy of the BJAM and mechanical strength of the parts for SS316L.
electron beam ADDITIVE MANUFACTURING PROCESS
References:
E. Soylemez, J.L. Beuth, and K. Taminger, “Controlling Melt Pool Dimensions over a Wide Range of Material Deposition Rates in Electron Beam Additive Manufacturing”, Solid Freeform Fabrication Proceedings, Proc.2010 Solid Freeform Fabrication Symposium, Austin, August 2010.
J.L. Beuth, J. Fox, J. Gockel, C. Montgomery, R. Yang, H. Qiao, E. Soylemez, P. Reeseewatt, A. Anvari, S. Narra, and N. Klingbeil, “Process Mapping for Qualification Across Multiple Direct Metal Additive Manufacturing Processes”, Solid Freeform Fabrication Proceedings, Proc.2013 Solid Freeform Fabrication Symposium, Austin, August 2013.
Electron beam melting process modeling
TUBITAK ARDEB 1003 funded EBM-PRO project focuses on cost effective and efficient process cycle for electron beam melting process. We mainly work on thermal modeling of the process. 2020 - 2024
References:
B. Kirim, E. Soylemez*, E. Tan, E. Yasa “Understanding Process Parameters Strategy to Simulate the Thermal Models of Electron Beam Melting”, Advances in Additive Manufacturing with Powder Metallurgy– AMPM22, p. 15-25, Jun 12-15, 2022, Portland, Oregon. Download
SELECTIVE LASER MELTING PROCESS
Melt Pool Modeling and Process Maps
E. Soylemez, “High deposition rate approach of selective laser melting through defocused single bead experiments and thermal finite element analysis for Ti-6Al-4V,” Additive Manufacturing, 31, 100984, 2020 https://doi.org/10.1016/j.addma.2019.100984
E. Soylemez, "Modelling the Melt Pool of the Laser Sintered Ti6Al4V Layers with Goldak’S Double-Ellipsoidal Heat Source", 29th Annual International Solid Freeform Fabrication Symposium, p. 1721-1736, 2018 http://sffsymposium.engr.utexas.edu/sites/default/files/2018/142%20ModellingtheMeltPooloftheLaserSinteredTi6A.pdf
Part-Scale Modeling
E. Soylemez, E. Koc, M. Coskun, “Thermo-Mechanical Simulations of Selective Laser Melting for AlSi10Mg Alloy to Predict the Part Scale Deformations,” Progress in Additive Manufacturing, 1 – 14, 2019 https://doi.org/10.1007/s40964-019-00096-4
FDM CASE STUDY: NEY MOUTHPIECE
Ney (reed flute) is one of the unique instruments that provides tunes in the wide range closest to the human voice. However, it is quite challenging to be master of the instrument. Some can not even acquire the sound. Additive manufacturing may provide a solution by designing the mouthpiece appropriate to more natural position for this wind instrument.
If you are interested this project, please contact.
FDM CASE STUDY: reducing washer for a door handle
FDM process shines especially when a plastic part spare part is needed. In this case, an old high quality door handle housing assembly needed a special size reducing washer. Even it is just a ring, the custom size was not available in the market. FDM provided the part, and it has been in service since 2017.
FDM CASE STUDY: BRITA Marella JUG cap
Ahmet Selim Koca, Mithat Can Ozin, Emrecan Soylemez
BRITA Jug’s filter cap was broken and we printed a replacement part to keep using the pitcher. First, broken pieces were glued and scanned by HP 3D Structured Light Scanner Pro S3. Then, scanned file was imported to Solidworks environment to modify into final form. After trial and error an STL file is established. We used that for FDM printing.
Printing Details
Ultimaker 2
Material is PLA
layer thickness 0.1 mm
infill 70%
used nozzle 0.4 mm
print speed 30 mm/s
Our goal was to replace the functional part to eliminate particles getting into the pitcher so we did not polish the part for a better look. You are welcome to upgrade files and do further process.
STL file is available on Thingiverse: https://www.thingiverse.com/thing:4763420
Class project examples
Ahmet Selim Koca, Mithat Can Ozin, Emrecan Soylemez
BRITA Jug’s filter cap was broken and we printed a replacement part to keep using the pitcher. First, broken pieces were glued and scanned by HP 3D Structured Light Scanner Pro S3. Then, scanned file was imported to Solidworks environment to modify into final form. After trial and error an STL file is established. We used that for FDM printing.
Printing Details
Ultimaker 2
Material is PLA
layer thickness 0.1 mm
infill 70%
used nozzle 0.4 mm
print speed 30 mm/s
Our goal was to replace the functional part to eliminate particles getting into the pitcher so we did not polish the part for a better look. You are welcome to upgrade files and do further process.
STL file is available on Thingiverse: https://www.thingiverse.com/thing:4763420