Optimal Design of Support Structures in Selective Laser Melting of Parts

Guoqing, 张国庆 Zhang; Yongqiang, 杨永强 Yang; Zimian, 张自勉 Zhang; Song, Changhui; Anmin, 王安民 Wang; Jiakuo, 余家阔 Yu

doi:10.3788/cjl201643.1202002

Cited by 8 publications

(5 citation statements)

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“…10 a. Based upon previous research on 3D printing part placement and support addition methods 15 , a tilted vertical placement approach was adopted for the battery pack upper tray, lower bracket, and lower tray bracket. To be specific, an angle of 75° between the molded part and the substrate was implemented to minimize the need for excessive support addition, particularly in critical areas such as the inner sections of the upper tray, lower bracket, and lower tray bracket, as illustrated in Fig.…”

Section: Resultsmentioning

confidence: 99%

Optimization design of battery bracket for new energy vehicles based on 3D printing technology

Zhang,

Li,

et al. 2024

Sci Rep

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Nowadays, what captures consumers' primary attention is how to purchase electric vehicles with long range and desirable price. Lightweight construction stands as one of the most effective approaches for prolonging range and lowering costs. As a consequence, it is particularly imperative to undertake lightweight design optimization for the battery bracket of new energy vehicles by applying 3D printing technology. To actualize this goal, Rhino software was initially employed for 3D modeling to design the battery bracket system for a pure electric vehicle in China. Subsequently, topology optimization design of the battery bracket was carried out by adopting Altair Inspire software. Last but not least, manufacturing and assembly inspection were completed using a 3D printer. The results show that the maximum displacement of the battery lower tray bracket after topology optimization is 3.20 mm, which is slightly higher than before, but still relatively small. The maximum Mises equivalent stress rose to 240.7 MPa post-optimization, but brought about a uniform stress distribution at the bottom of the bracket. In comparison, the minimum factor of safety met design requirements at 1. The mass was lessened to 0.348 kg, representing a 49.2% decrease in comparison with pre-optimization levels. The 3D-printed bracket was fabricated by employing a 3D printer, thereby achieving the aforementioned mass abatement. The battery pack parts exhibited a bright surface with low roughness and no discernible warping or deformation defects. As revealed by the assembly results, the components of the battery pack bracket are tightly coordinated with each other, with no evident assembly conflicts, revealing that the dimensional accuracy and fit of the completed parts meet production requirements. These findings lay solid groundwork for the mass production of high-performance battery pack brackets.

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Section: Resultsmentioning

confidence: 99%

Optimization design of battery bracket for new energy vehicles based on 3D printing technology

Zhang,

Li,

et al. 2024

Sci Rep

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“…Considering the large machining section, the preheating temperature of the substrate and the addition of 25% supports can be appropriately increased to reduce the stress concentration and avoid buckling deformations. When using SLM technology to shape the curved guide plate, previous studies on the placement and support addition mode of SLM formed parts have revealed that the plane of the guide plate holder should be inclined to the machining datum plane by 55° to avoid a large machining section, reduce stress concentration and add multiple holders (Zhang et al 19 ). Moreover, to further understand the machining risks of curved guide plates, we analyzed the machining risks using Magics software 22.0 (Fig.…”

Section: Resultsmentioning

confidence: 99%

Optimized design and key performance factors of a gas circulation filtration system in a metal 3D printer

Zhang

Zhou

et al. 2022

Sci Rep

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To further improve the quality of parts in metal 3D printers, it is necessary to optimize the structure and study the performance of their gas circulation filtration systems. First, we used the parametric modeling method to complete the formed cavity modeling. We then optimized the design of the air inlet structure of the formed cavity using the moldflow simulation method, and finally, we evaluated the optimized design results through assembly experiments and measurements of the molded parts’ components. The combination of parametric modeling and moldflow simulation methods produced a high modeling efficiency and had a good effect on the optimized design of the gas circulation filtration systems. After optimizing the design, the turbulence intensities and distribution areas of the formed cavities were reduced. During the 3D printing of the curved guide plate, the plane of the guide plate holder was inclined 55° relative to the machining datum plane, which improved the form quality. The 3D printed curved guide plate closely matched the inlet end of the printer’s air duct, and the upper guide plate was fixed at a suitable position using screws. The niobium contents of the parts formed by the guide plate in Design 2 were low, which lays a foundation for the 3D printing of high-performance metal parts.

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“…The way support is added and placed for 3D-printed parts is related to the quality of the formed parts [13]. To gain deeper insights into the machining risk associated with the "Guardian" jewelry model, a comprehensive machining risk analysis was executed utilizing Magics software.…”

Section: Data Processing For 3d-printed Jewelrymentioning

confidence: 99%

Research on Key Technologies of Jewelry Design and Manufacturing Based on 3D Printing Technology

Zhang,

Wang,

et al. 2024

Coatings

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In conjunction with the swift enhancement of China’s economic prowess, the demand for jewelry among the populace is gradually evolving towards personalized, customized, and intricate designs. Traditional manufacturing approaches are increasingly inadequate to meet these evolving demands. However, the advent of 3D printing technology presents a viable solution for the direct fabrication of such sophisticated jewelry. To this end, the conceptualization of personalized jewelry inspiration is initiated, followed by the implementation of parametric design using SolidWorks 2018 software. Subsequently, 3D printing technology is employed to materialize the jewelry directly. Results indicate that the “Guardian” jewelry model, crafted through the parametric modeling method, exhibits a commendable design, and adheres to processing requirements following a comprehensive risk analysis. The strategic adjustment of the jewelry’s position effectively reduces the required support, circumventing the necessity of adding support to critical surfaces. The surface of the Selective Laser Melting (SLM)-manufactured “Guardian” jewelry boasts a lustrous finish, showcasing optimal overlap between pillars and excellent connectivity among pores. Minimal powder adherence on the surface is observed, enabling direct utilization post-sandblasting, polishing, and plating. This establishes a solid foundation for the direct application of SLM-manufactured personalized jewelry.

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Optimal Design of Support Structures in Selective Laser Melting of Parts

Cited by 8 publications

References 0 publications

Optimization design of battery bracket for new energy vehicles based on 3D printing technology

Optimization design of battery bracket for new energy vehicles based on 3D printing technology

Optimized design and key performance factors of a gas circulation filtration system in a metal 3D printer

Research on Key Technologies of Jewelry Design and Manufacturing Based on 3D Printing Technology

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