Design and modeling of abrasive flow finishing of freeform surfaces of FDM printed femoral component of knee implant pattern

Hashmi, Abdul Wahab; Mali, Harlal Singh; Meena, Anoj; Saxena, Kuldeep K.; Puerta, Ana Pilar Valerga; Rao, U. Sathish; Buddhi, Dharam; Mohammed, Kahtan A.

doi:10.1007/s12008-022-01048-z

Cited by 4 publications

(3 citation statements)

References 78 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The field of orthopedics is undergoing a revolution because of EBM 3D printing, which produces highly functional and customized implants, like Co-Cr-Mo femoral appliances. In the past, femoral appliances were produced using casting or machining methods, which imposed restrictions on customization and intricate shapes [160][161][162]. The utilization of EBM 3D-printing technology to create Co-Cr-Mo femoral appliances signifies a notable breakthrough in the field of orthopedic surgery.…”

Section: Biomedical Implantsmentioning

confidence: 99%

Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review

Joshua,

Raj,

Hameed Sultan

et al. 2024

Materials

View full text Add to dashboard Cite

Precision manufacturing requirements are the key to ensuring the quality and reliability of biomedical implants. The powder bed fusion (PBF) technique offers a promising solution, enabling the creation of complex, patient-specific implants with a high degree of precision. This technology is revolutionizing the biomedical industry, paving the way for a new era of personalized medicine. This review explores and details powder bed fusion 3D printing and its application in the biomedical field. It begins with an introduction to the powder bed fusion 3D-printing technology and its various classifications. Later, it analyzes the numerous fields in which powder bed fusion 3D printing has been successfully deployed where precision components are required, including the fabrication of personalized implants and scaffolds for tissue engineering. This review also discusses the potential advantages and limitations for using the powder bed fusion 3D-printing technology in terms of precision, customization, and cost effectiveness. In addition, it highlights the current challenges and prospects of the powder bed fusion 3D-printing technology. This work offers valuable insights for researchers engaged in the field, aiming to contribute to the advancement of the powder bed fusion 3D-printing technology in the context of precision manufacturing for biomedical applications.

show abstract

Section: Biomedical Implantsmentioning

confidence: 99%

Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review

Joshua,

Raj,

Hameed Sultan

et al. 2024

Materials

View full text Add to dashboard Cite

show abstract

“…Our findings align with recent studies indicating the effectiveness of abrasive flow machining in improving the micro geometry of polymer-based gears. Reducing surface roughness, not only improves the aesthetic and functional qualities of FDM-printed gears but also contributes to a broader understanding of the interplay between polymer science and additive manufacturing techniques [33,41]. Figure 25 is a probability plot of the percentage improvement of Ra, assessing the normality of data distribution.…”

Section: Duration To Finish Versus Percentage Improvement Of Ramentioning

confidence: 99%

Optimizing surface finish in FDM-printed polycarbonate spur gears through abrasive flow finishing: insights from physics and material science perspectives

Meena,

Hashmi,

Iqbal

et al. 2024

Phys. Scr.

Self Cite

View full text Add to dashboard Cite

In recent times, the usage of polymers has experienced notable growth across diverse manufacturing sectors. Polymeric gears, integral to automation, material handling systems, toys, and household appliances, have become ubiquitous. Although additive manufacturing techniques, especially Three-Dimensional (3D) printing, offer versatile applications, they grapple with challenges, notably poor surface finishing attributed to layer accumulation. This work explores the field of abrasive flow machining (AFM) in experimental settings using FDM-printed polymeric gears. The AFM medium concoction involves coal ash powder as the foundational material, EDM oil as the carrier fluid, and the infusion of glycerin as additives. Rigorous investigations were undertaken to pinpoint the optimal viscosity of the AFM medium and refine process parameters with a central focus on enhancing surface quality. A Taguchi L9 Design of Experiment (DOE) was meticulously crafted for parameter optimization using the Minitab statistical software. The investigation established a functional relationship between the output parameter (surface roughness) and key input variables (layer thickness, abrasive percentage, abrasive mesh size, and finishing time). The maximum level of AFM media optimization was attained at 33% abrasive concentration, 220 abrasive mesh size, and 60% liquid synthesizer. Additionally, the results of the investigation showed that a media viscosity of 0.50 Pa-sec, layer thickness of 0.1, and culminating time of 45 min were the optimal values for the most % improvement in surface roughness. The initial surface roughness underwent a profound reduction from 12.30 μm to 0.30 μm, marking an exceptional improvement of 97.56%. This inquiry contributes significant insights into the refinement of AFM parameters for elevating the surface finish of FDM-printed polymeric gears, promising enhanced performance across diverse applications.

show abstract

“…The mechanical postprocessing are categorized into cutting-based (Karthick Raaj et al, 2020), abrasive-based (Basha et al, 2023;Hashmi et al, 2023c;Zheng et al, 2023) and pressure-based methods (Calignano et al, 2022;García de la Torre et al, 2023) pursuant to their fundamental principles of polishing mechanism (Hashmi et al, 2021). In cutting tool-based and abrasive-based polishing techniques, the continuous contact of the cutting tools or abrasive media and the surface of the printed object provides a controlled material removal from the peak portions of the surface profile without any substantial changes in the valley portions of the surface profile (Barzegar et al, 2022;Hashmi et al, 2022a;Hashmi et al, 2022b). In pressure-based finishing strategy, the interaction force between the pressing tool and the exterior face of the printed subject provides a limited permanent deformation on the surface profile without further removal of material.…”

Section: Introductionmentioning

confidence: 99%

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

Barzegar,

Farahani,

Gomroki

2024

RPJ

View full text Add to dashboard Cite

Purpose Material extrusion-based additive manufacturing is a prominent manufacturing technique to fabricate complex geometrical three-dimensional (3D) parts. Despite the indisputable advantages of material extrusion-based technique, the poor surface and subsurface integrity hinder the industrial application of this technology. The purpose of this study is introducing the hot air jet treatment (HAJ) technique for surface treatment of additive manufactured parts. Design/methodology/approach In the presented research, novel theoretical formulation and finite element models are developed to study and model the polishing mechanism of printed parts surface through the HAJ technique. The model correlates reflow material volume, layer width and layer height. The reflow material volume is a function of treatment temperature, treatment velocity and HAJ velocity. The values of reflow material volume are obtained through the finite element modeling model due to the complexity of the interactions between thermal and mechanical phenomena. The theoretical model presumptions are validated through experiments, and the results show that the treatment parameters have a significant impact on the surface characteristics, hardness and dimensional variations of the treated surface. Findings The results demonstrate that the average value of error between the calculated theoretical results and experimental results is 14.3%. Meanwhile, the 3D plots of Ra and Rq revealed that the maximum values of Ra and Rq reduction percentages at 255°C, 270°C, 285°C and 300°C treatment temperatures are (35.9%, 33.9%), (77.6%,76.4%), (94%, 93.8%) and (85.1%, 84%), respectively. The scanning electron microscope results illustrate three different treatment zones and the treatment-induced and manufacturing-induced entrapped air relief phenomenon. The measured results of hardness variation percentages and dimensional deviation percentages at different regimes are (8.33%, 0.19%), (10.55%, 0.31%) and (−0.27%, 0.34%), respectively. Originality/value While some studies have investigated the effect of the HAJ process on the structural integrity of manufactured items, there is a dearth of research on the underlying treatment mechanism, the integrity of the treated surface and the subsurface characteristics of the treated surface.

show abstract

Design and modeling of abrasive flow finishing of freeform surfaces of FDM printed femoral component of knee implant pattern

Cited by 4 publications

References 78 publications

Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review

Powder Bed Fusion 3D Printing in Precision Manufacturing for Biomedical Applications: A Comprehensive Review

Optimizing surface finish in FDM-printed polycarbonate spur gears through abrasive flow finishing: insights from physics and material science perspectives

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

Contact Info

Product

Resources

About