Abstract
The additive manufacturing (AM) applications have attracted a great deal of interest with regard to experimental aerodynamic studies. There is a need for a universal roughness scale that characterizes different materials used in aerodynamic research. The main purpose of this paper is identification of the potential of a material jetting AM process to produce accurate aerodynamic surfaces. A new methodology to evaluate the roughness of aerodynamic profiles (airfoils) was proposed. A very short-span wing artifact for preliminary tests and a long-span wing model were proposed for design of experiments. Different artifacts orientations were analyzed, maintaining the same surface quality on the upper and lower surface of the wing. A translucent polymeric resin was used for samples manufacturing by polymer jetting (PolyJet) technology. The effects of main factors on the surface roughness of the wing were investigated using the statistical design of experiments. Three interest locations, meaning the leading-edge, central, and trailing-edge zones, on the upper and lower surfaces of the airfoil were considered. The best results were obtained for a sample oriented at XY on the build platform, in matte finish type, with a mean Ra roughness in the range of 2 to 3.5 μm. Microscopy studies were performed to analyze and characterize the surfaces of the wing samples on their different zones.
Highlights
Introduction and Wai Yee YeongAdditive manufacturing (AM), known as 3D printing, represents a key technology in the implementation of Industry 4.0 [1], based on its ability to fabricate highly complex and lightweight components directly from computer-aided design (CAD) files, saving time, cost, and effort
There is a need for a universal roughness scale that can describe every type of roughness for different materials used in aerodynamic studies
The experimental surface roughness distribution on the upper and lower surface of the airfoil printed in two different quality modes and different orientations on the build platform; Surface quality issues of airfoil samples; The experimental analysis by microscopy of airfoils printed in different orientation; Results of statistical analysis
Summary
Introduction and Wai Yee YeongAdditive manufacturing (AM), known as 3D printing, represents a key technology in the implementation of Industry 4.0 [1], based on its ability to fabricate highly complex and lightweight components directly from computer-aided design (CAD) files, saving time, cost, and effort. Seven categories of AM processes are defined by ISO/ASTM 52900-15 [2] standard based on the different joining techniques of materials to make parts from 3D model data, as follows: vat photo-polymerization (VP), binder jetting (BJ), material extrusion (ME), material jetting (MJ), sheet lamination (SL), powder bed fusion (PBF), and directed energy deposition (DED). Material jetting processes, which include polymer jetting (PolyJet) and multi-jet printing (MJM) technologies, can be defined as a technique that selectively deposits droplets of material and cured them onto a build platform. The main materials types used in the seven individual AM processes described by AM standards are polymers, ceramics, metals, and composite materials. Polymers became very popular in AM being used in the most of the AM processes and targeting a variety of applications [4]
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