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Applied Sciences
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Additive Manufacturing in Automotive, Aerospace and Marine Engineering
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Additive Manufacturing in Automotive, Aerospace and Marine Engineering

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (20 October 2021) | Viewed by 10130

Special Issue Editors

Prof. Dr. Alessandro Ceruti

E-Mail Website
Guest Editor
Department of Industrial Engineering (DIN), University of Bologna, 40136 Bologna/Forlì, Italy
Interests: multidisciplinary optimisation; additive manufacturing; lattice structures and topological optimisation; aerospace and industrial engineering; augmented reality
Prof. Dr. Sara Mantovani

E-Mail Website
Guest Editor
Department of Engineering ‘’Enzo Ferrari’’, Università degli Studi di Modena e Reggio Emilia, 41125 Modena, Italy
Interests: automotive and mechanical engineering; multidisciplinary and topological optimisation; additive manufacturing; lattice structures; machine design problem; automotive chassis design; advanced finite element modelling

Special Issue Information

Dear Colleagues,

Interest in additive manufacturing (AM) is rapidly increasing in academia and industry, especially in automotive, aerospace, and marine engineering. The present Issue offers an exchange platform for the AM research and the practitioner community to address the most outstanding advances in AM research through modelling, experimental–numerical correlation, process challenges, and optimisation. An understanding of the fundamental relationships between materials and the processing environment is pursued. Both theoretical and experimental contributions can be submitted.

The following topics are encouraged, but also other contributions in the AM field could be evaluated:

  1. AM in automotive, aeronautical, space, and marine engineering;
  2. Design tools for AM: topology optimisation, multi-disciplinary optimisation, and support design;
  3. Feedback control methods and process mapping for minimizing defects and residual stress in as-built structures;
  4. Fatigue, crash behaviour, and fracture modes of AM components;
  5. Materials for AM manufacturing (metallic powders, resins, and filaments) modelling considering effects of printing direction and microstructure;
  6. AM products’ life cycle design and assessment, and new methods and tools for assessing the economic and environmental impact of AM technologies;
  7. Thermal treatments, dimensional accuracy and surface finish, and in-situ process metrology;
  8. Standards and regulations for AM.

Prof. Dr. Alessandro Ceruti
Prof. Dr. Sara Mantovani
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing applications
  • design and optimisation
  • numerical simulation
  • material properties
  • technology and manufacturing

Published Papers (4 papers)

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Research

19 pages, 4819 KiB  
Article
Analysis of a Preliminary Design Approach for Conformal Lattice Structures
by Pierandrea Dal Fabbro, Stefano Rosso, Alessandro Ceruti, Diego Boscolo Bozza, Roberto Meneghello, Gianmaria Concheri and Gianpaolo Savio
Appl. Sci. 2021, 11(23), 11449; https://doi.org/10.3390/app112311449 - 2 Dec 2021
Cited by 4 | Viewed by 3557
Abstract
An important issue when designing conformal lattice structures is the geometric modeling and prediction of mechanical properties. This paper presents suitable methods for obtaining optimized conformal lattice structures and validating them without the need for high computational power and time, enabling the designer [...] Read more.
An important issue when designing conformal lattice structures is the geometric modeling and prediction of mechanical properties. This paper presents suitable methods for obtaining optimized conformal lattice structures and validating them without the need for high computational power and time, enabling the designer to have quick feedback in the first design phases. A wireframe modeling method based on non-uniform rational basis spline (NURBS) free-form deformation (FFD) that allows conforming a regular lattice structure inside a design space is presented. Next, a previously proposed size optimization method is adopted for optimizing the cross-sections of lattice structures. Finally, two different commercial finite element software are involved for the validation of the results, based on Euler–Bernoulli and Timoshenko beam theories. The findings highlight the adaptability of the NURBS-FFD modeling approach and the reliability of the size optimization method, especially in stretching-dominated cell topologies and load conditions. At the same time, the limitation of the structural beam analysis when dealing with thick beams is noted. Moreover, the behavior of different kinds of lattices was investigated. Full article
(This article belongs to the Special Issue Additive Manufacturing in Automotive, Aerospace and Marine Engineering)
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13 pages, 39315 KiB  
Article
Assessment of Computer-Aided Design Tools for Topology Optimization of Additively Manufactured Automotive Components
by Enrico Dalpadulo, Fabio Pini and Francesco Leali
Appl. Sci. 2021, 11(22), 10980; https://doi.org/10.3390/app112210980 - 19 Nov 2021
Cited by 11 | Viewed by 2076
Abstract
The use of Topology Optimization techniques has seen a great development since the last decade. The principal contributor to this trend is the widespread use of Additive Manufacturing technologies to effectively build complex and performant structures over different settings. Nevertheless, the use of [...] Read more.
The use of Topology Optimization techniques has seen a great development since the last decade. The principal contributor to this trend is the widespread use of Additive Manufacturing technologies to effectively build complex and performant structures over different settings. Nevertheless, the use of Topology Optimization in Design for Additive Manufacturing processes is not simple and research aims to fill the gap between theory and practice by evolving at the same time both approaches, workflows, and design software that allow their implementation. Since a strong connection between methodologies and tools exists, this work proposes a method to assess computer-aided design tools or platforms. This can be applied to sustain the key phase for selection and adoption of the computer-aided tools in industrial settings embracing Additive Manufacturing. The workflow for Topology Optimization implementation, the structure of the proposed evaluation approach, and its application, are presented to demonstrate effective usability. The automotive case study is the redesign of internal combustion engine piston to benefit of metal Additive Manufacturing based enhanced product performance. A preliminary finite element model is defined and a Topology Optimization based redesign is concurrently set up through four different commercial computer-based platforms. The method accounting for the assessment of required operations for the design optimization is applied to perform the tools selection phase. Full article
(This article belongs to the Special Issue Additive Manufacturing in Automotive, Aerospace and Marine Engineering)
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22 pages, 11364 KiB  
Article
Squashed-Slice Algorithm Based on STEP-NC for Multi-Material and Multi-Directional Additive Processes
by Jumyung Um, Joungmin Park and Ian Anthony Stroud
Appl. Sci. 2021, 11(18), 8292; https://doi.org/10.3390/app11188292 - 7 Sep 2021
Cited by 5 | Viewed by 1765
Abstract
Even though additive manufacturing is receiving increasing interest from aerospace, automotive, and shipbuilding, the legacy approach using tessellated form representation and cross-section slice algorithm still has the essential limitation of its inaccuracy of geometrical information and volumetric losses of final outputs. This paper [...] Read more.
Even though additive manufacturing is receiving increasing interest from aerospace, automotive, and shipbuilding, the legacy approach using tessellated form representation and cross-section slice algorithm still has the essential limitation of its inaccuracy of geometrical information and volumetric losses of final outputs. This paper introduces an innovative method to represent multi-material and multi-directional layers defined in boundary-representation standard model and to process complex sliced layers without missing volumes by using the proposed squashing operation. Applications of the proposed method to a bending part, an internal structure, and an industrial moulding product show the assurance of building original shape without missing volume during the comparison with the legacy method. The results show that using boundary representation and te squashing algorithm in the geometric process of additive manufacturing is expected to improve the inaccuracy that was the barrier of applying additive process to various metal industries. Full article
(This article belongs to the Special Issue Additive Manufacturing in Automotive, Aerospace and Marine Engineering)
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20 pages, 10891 KiB  
Article
An Accelerated Slicing Algorithm for Frep Models
by Evgenii Maltsev, Dmitry Popov, Svyatoslav Chugunov, Alexander Pasko and Iskander Akhatov
Appl. Sci. 2021, 11(15), 6767; https://doi.org/10.3390/app11156767 - 23 Jul 2021
Cited by 4 | Viewed by 1821
Abstract
Complex 3D objects with microstructures can be modelled using the function representation (FRep) approach and then manufactured. The task of modelling a geometric object with a sophisticated microstructure based on unit cell repetition is often too computationally expensive for CAD systems. FRep provides [...] Read more.
Complex 3D objects with microstructures can be modelled using the function representation (FRep) approach and then manufactured. The task of modelling a geometric object with a sophisticated microstructure based on unit cell repetition is often too computationally expensive for CAD systems. FRep provides efficient tools to solve this problem. However, even for FRep the slicing step required for manufacturing can take a significant amount of time. An accelerated slicing algorithm for FRep 3D objects is proposed in this paper. This algorithm allows the preparation of FRep models for 3D printing without surface generation stage. The spatial index is employed to accelerate the slicing process. A novel compound adaptive criterion and a novel acceleration criterion are proposed to speed up the evaluation of the defining function of an FRep object. The use of these criteria is significantly reducing the computational time for contour construction during the slicing process. The K-d tree and R-tree data structures are used as spatial indexes. The performance of the accelerated slicing algorithm was tested. The contouring time was reduced 100-fold due to using the novel compound adaptive criterion with the novel acceleration criterion. Full article
(This article belongs to the Special Issue Additive Manufacturing in Automotive, Aerospace and Marine Engineering)
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