Forthcoming articles

 


International Journal of Rapid Manufacturing

 

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International Journal of Rapid Manufacturing (7 papers in press)

 

Regular Issues

 

  • The Performance of Tool Shape on Efficiency and Quality of forming in Incremental Sheet Forming Process   Order a copy of this article
    by Bhavin Desai, Keyur P. Desai, Harit K. Raval 
    Abstract: Incremental Sheet Forming Process (ISFP) is an economical alternative of conventional sheet metal forming process to manufacture parts in small or medium batch size as well as to produce sheet metal prototypes. In present investigation, to study the effect of tool shape on efficiency and quality of the formed component, two different kind of tools of same diameter with hemispherical end and spherical end are employed. Forming time is considered as a measure of process efficiency and profile accuracy as quality of forming. The Taguchi experimental design is applied for experimentation. ANOVA is performed to know the level of significance of the process parameters. It is found that incremental depth step is the most significant process parameter affecting forming efficiency followed by forming speed (feed). While forming speed, wall angle and incremental depth step are most significant parameters, which affects the forming quality.
    Keywords: Incremental sheet forming; Taguchi; ANOVA; Profile accuracy.

  • Friction and wear rate characteristics of parts manufactured by Fused Deposition Modelling process   Order a copy of this article
    by Pavan Kumar Gurrala 
    Abstract: The present research work aims at understanding the effect of FDM (Fused deposition modelling) process parameters on tribological properties like friction and wear rate. Two Pin-on-Disc (PoD) parameters namely normal load and sliding speed have been chosen. Orientation angle of the part is chosen as the third varying parameter. Test specimens are manufactured as per the design of experiments (DOE) set-up. Response surfaces and the interaction effects of the process parameters are studied through response surface methodology (RSM). Analysis of Variance (ANOVA) results indicate that there is substantial interaction effect of part build orientation angle on comparison with the other two parameters on the tribological properties of parts. Scanning Electron Microscope (SEM) micrographs of the worn surfaces reveal the importance of part build orientation and its contribution towards the surface strength properties. The tribological studies conclude that cracks are formed in the specimens when tested at high load, high speed and low part build orientation angle of the part.
    Keywords: Fused deposition modelling; friction; wear; Pin-on-Disc; ANOVA.

  • Producing parts with multiple layer thicknesses by projection stereolithography   Order a copy of this article
    by Pekka Lehtinen, Harri Korhonen, Jukka Seppälä, Matti Kaivola, Jouni Partanen 
    Abstract: We present a novel method to increase the manufacturing speed and versatility in lithography-based additive manufacturing processes. Usually a part made with additive manufacturing consists of equally thick layers that are fabricated upon one another. We use a projection stereolithography (PSL) system to manufacture parts containing several layer thicknesses, which reduces the manufacturing time and adds controllability to the system. The method is based on the possibility to control the cure depth by adjusting the operation wavelength. To demonstrate the applicability of the PSL system for this purpose, we used two different operation wavelengths to produce parts that include 50
    Keywords: stereolithography; SL; SLA; projection stereolithography; PSL; 3D printing; additive manufacturing; AM; layer thickness; penetration depth; cure depth; multiple layers; photopolymers.

  • Project InnoDino: Additively Innovative Dinosaur Design and Manufacturing   Order a copy of this article
    by Ismail Fidan 
    Abstract: Additive manufacturing (AM) is a quickly growing field and promises to be revolutionary to the manufacturing industry and to society. One novel application of AM is the ability to recreate history and make the past come alive to present day audiences. One of the major challenges that must be overcome for AM technologies to become ubiquitous in society is the joining of 3D printed parts. For many applications, parts must be able to move relative to each other which requires the use of joints. Another challenger is the limited capacity of most printer beds on the market today. To make large scale, functional parts, 3D printed pieces must be joined or fused in order to make large, continuous parts. Both of these challenges are explored within the context of recreating a struthiomimus dinosaur by completely 3D printing and assembling the dinosaur. This current paper reports the milestones in making a struthiomimus dinosaur.
    Keywords: Additive Manufacturing; Design; Reverse Engineering; Joint; Assembly; Dinosaur.

  • Surface Roughness Improvement using Volumetric Error Control through Adaptive Slicing   Order a copy of this article
    by Mohammad Taufik, Prashant K. Jain 
    Abstract: This research presents the development of the advanced adaptive slicing procedure to improve the surface roughness by adaptively selecting the layer thickness based on the user specified volumetric error (VE) value bound. However, most of the researchers have developed slicing procedures to improve the part surface quality under cusp height/stair-stepping error concept. On the other hand, limitation of cusp height based basic adaptive slicing procedures is that it does not have any direct control on VE. It is quite possible that with a very little variation in cusp height a large variation in VE may occur on shallow surfaces. In contrast, the advanced adaptive slicing algorithm has been developed and implemented to vary layer thickness directly under a specified VE value on the FDM part surfaces although process can also be useful for all AM processes to control VE. In the present work, different models have been used to estimate VE and surface roughness according to the layer thickness changes.
    Keywords: Additive manufacturing (AM); Surface roughness; volumetric error.

  • Additive Manufacturing of H13 Tooling Element with Conformal Cooling Channel Using MIG Cladding   Order a copy of this article
    by Fisseha Legesse, Sajan Kapil, Hari Vithasth, K.P. Karunakaran 
    Abstract: Hybrid Layered Manufacturing (HLM) is a synergic integration of additive and subtractive manufacturing processes. It takes the positive aspects of both the processes such as accuracy through subtractive and reduction of material through additive. In this work, The Metal Inert Gas (MIG) cladding has been used for addition and CNC milling machining is used for subtraction. The process parameters for MIG cladding of H-13 tool steel material was investigated using Taguchi DOE method. The effect of different process parameters such as current, torch speed and standoff distance, on weld bead width, height and penetration have been studied using ANOVA. This paper describes the methodology of analyzing and manufacturing of a die element using H13 tool steel material with a proper conformal cooling channel and in-situ preheating process using an induction heating system.
    Keywords: Hybrid Layered Manufacturing; Baffle & Bubbler cooling; MIG Cladding; In-situ preheating.

  • Multi Objective Optimization of Fused Deposition Modelling process parameters using RSM and fuzzy logic for build time and support material   Order a copy of this article
    by Manu Srivastava 
    Abstract: Additive Manufacturing (AM) is around three-decade old technology and enables quick transition from concept to physical models in a matter of hours. Fused deposition modelling (FDM) is a promising and robust AM technique with proven ability to build prototypes of complex and intricate shapes using reasonable time and cost. Optimization of FDM process requires optimization of various qualitative and quantitative responses. This work presents multi-objective FDM optimization using RSM embedded fuzzy logic analysis. Six process parameters and two responses are considered for the current experimentation on Fortus 250mc modeller based on FDM technology.
    Keywords: Additive manufacturing; Fused deposition modelling; Build time; Support material Volume; Response surface methodology; Fuzzy logic.