Digital Twin (DT) is a modern concept that allows for the creation of the digital model of the manufacturing process, and hence for the product life-cycle monitoring. DT could provide manufacturing details and identify potential shifts and anomalies during printing. It has a significant potential in additive manufacturing as an avenue to address manufacturing uncertainties. In this study, the digital twin for the fused deposition modeling method of the additive manufacturing was developed. DT provides information about the speed of sound within the material. Information about the sound speed is used to evaluate the elastic properties of printed material. The results of sound speed measurements in the PLA samples printed using various combinations of parameters of the printing process are analyzed. Using the measurements results, the response surface linking the elastic properties of the material to the parameters of the printing process is established. Based on the information about speed of sound within the material, further actions could be taken on the adjustment of the printing process in order to obtain desirable properties. An analytical model of the sound speed propagation within the material was developed and evaluated using the experimental data. It is suggested that DT combined with the printing response surface is a valuable approach to control of the printing process. This integrated approach demonstrates considerable promise in steering additive manufacturing towards the attainment of specified material properties.
Ultrasonic testing (UT) - is one of the most widely used nondestructive evaluation methods. A renewed interest in the ultrasonic methods is prompted by the needs of the quality control of additively manufactured products. In additive manufacturing (AM), challenges of the ultrasonic evaluation include considerations of elaborate geometry of AM parts, small size of specimens, coupling issues and complex material compositions. Application of ultrasonic testing in AM promises to improve reliability of printed parts and to reduce the number of printing cycles which, consequently, could reduce the manufacturing costs. In this contribution, the authors suggest an approach to determine the mechanical properties of the additively manufactured dog-bone specimens. Small-scale specimens complied to ASTM standard were fabricated from aluminum alloys. An ultrasonic testing methodology was developed to assess elastic properties of the specimens. Frequencies of the excitation were selected to best match geometrical constraints and address the ultrasonic attenuation. Elastic wave propagation characteristics were measured at various locations yielding spatially distributed properties. A signal analysis algorithm was developed and implemented to extract elastic properties from the ultrasonic data. Conclusions regarding applicability of the developed methodology to additive manufacturing are suggested and future work is discussed.
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