Search

Digital twin and additive layer manufacturing plays a vital role of the fourth industrial revolution. Digital twin is the ideal solution for data-driven optimisation of additive manufacturing challenges. It is helpful in understating, analysing, and improving 3D printing machining process variables and consequently reducing the number of trial-and-error and component’s non-conformance and shorten product development lead time. Furthermore, the development of genuine digital twin still requires more research efforts to develop a thorough understanding of its concept, data management framework, and development techniques. Therefore, this paper aims to capture important data-driven digital twin requirements for additive layer manufacturing through a systematic approach by identifying the requirements, analysing technologies and processes for digital twin development. The main novelty of this research is applying a holistic approach to build digital twin of additive manufacturing process by capturing the requirements from both literature review and world-class aerospace industrial experts. Overall, the captured requirements will not only serve industries as a basis for implementing digital twin for additive manufacturing and modernize existing data management systems but also opens new research areas in the digital twin domain.

Warpage is one of the prominent issues in Fused Filament Fabrication. The cause of this is the rapid cooling of the polymer during extrusion. The residual thermal stresses accumulated within the print part result in a shape distortion and subsequent detachment of the object from the print bed. In this study, both experimental and numerical approaches were used to identify the stresses due to thermal shrinking that occurs in soft polymers such as wax. A temperature sweep test was performed using a rotational rheometer to measure the magnitude of axial forces that are generated due to the thermal shrinking of a thin layer of 3D printable wax. The thermal stresses responsible for warpage were computed analytically and using the FEA. It was found that due to thermal processes, the stress magnitude can reach a value of 1.17 MPa. This value is enough to cause the plastic deformation in the wax part having a thin elongated shape. In addition, Taguchi's robust design has identified two major FFF parameters that impact the warpage in amorphous soft polymers. They are the printing speed and the print bed temperature. To achieve a low level of warpage, it is important to make sure that the layer deposition occurs at medium speeds and the print bed temperature is moderately high according to the findings of this study. [ABSTRACT FROM AUTHOR]

Initially, density approximations and generalised gradient approximations (GGA) functional of DFT were executed to determine the electronic structure where the non-local functionals of GGA obtained more close value of reference value, so that GGA method was used to calculate the band structures, DOS, PDOS and optical properties of ZrO2, Zr0.93Si0.07O2 and Zr0.86Si0.14O2 using the Perdew–Burke–Ernzerhof (PBE), Revised Perdew–Burke–Ernzerhof (RPBE), Perdew Wang (PW91), and Wu-Cohen. The transferability of electrons is completely related to PseudoPotential (PP), where four methods, such as OTFG ultra-soft, OTFG norm-conserving, ultra-soft, and norm-conserving, were used in this study. Finally, the norm-conserving PP has been selected as the most accurate method for determination of electronic structure. In addition, to assess the nature of orbital, the DOS and PDOS were additionally simulated and even the optical properties of crystals were calculated. Furthermore, the chemical reactivity, such as HOMO and LUMO, quantum properties, is justified where doping can have a vast effect as well as the open circuit voltage (Voc) is increased after doping. Finally, the toxicity data from in silico study refers to us that these are non-toxic or non-carcinogenic materials with not readily biodegradable status. [ABSTRACT FROM AUTHOR]