Nurhasyimah Abd Aziz, Lenggeswaran Elanggoven, Dzuraidah Abd Wahab, Nur Alia Shazmin Zakaria, Nadhira Fathiah Kamarulzaman, Nurfadzylah Awang
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Brake caliper housing is selected as a remanufacturable component for case exemplary purposes. Prior to analysis, the potential damages and failures of the brake caliper component were initially evaluated through literature surveys and direct interviews with industry experts where two types of damages were identified, namely, cracks and broken or fractured parts. Then, the validation focuses on comparative analysis of two different conditions of the brake caliper housing: original, and repaired caliper model using finite element analysis in ANSYS. Results indicate that the strength of the repaired caliper model shows equal and higher strength compared with the original model. This result confirms that the repair process through AM can retain or improve the quality of the remanufactured brake caliper housing. 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引用次数: 0
摘要
将增材制造(AM)作为一种自动修复方法,可实现可持续的再制造过程,这就是增材修复。尽管增材制造具有提高维修和修复效率的潜力,但其仍处于起步阶段,需要对部件设计和工艺参数进行深入研究。添加剂修复的主要问题是能否在两种金属之间形成完美的结合,这将影响整个修复部件的机械性能。因此,从一开始就进行评估至关重要,以便通过适当的结构分析验证工艺的可行性,并获得变形和应力结果。本案例选择制动钳壳体作为可再制造部件进行示例。在分析之前,通过文献调查和与行业专家的直接访谈,初步评估了制动钳部件的潜在损坏和故障,确定了两种损坏类型,即裂纹和破损或断裂部件。然后,利用 ANSYS 的有限元分析对制动钳外壳的两种不同情况进行比较分析,即原始制动钳模型和修复后的制动钳模型。结果表明,修复后的制动钳模型与原始模型相比,强度相当且更高。这一结果证实,通过 AM 进行修复可以保持或提高再制造制动钳壳体的质量。因此,本文结合失效分析技术,为多金属添加剂修复中的机械性能评估提供了一个系统框架。
Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper
The inclusion of additive manufacturing (AM) as an automated repair method leads to a sustainable remanufacturing process, which is known as additive repair. Despite its potential in improving the efficiency of repair and restoration, additive repair remains in its infancy and requires a thorough investigation on part design and process parameters. The major concern raised in additive repair is the capability to create perfect bonding between two metals, which will affect the mechanical properties of the complete repaired part. Hence, performing evaluation from the beginning is crucial to validate the feasibility of the process through appropriate structural analysis and to obtain deformation and stress results. Brake caliper housing is selected as a remanufacturable component for case exemplary purposes. Prior to analysis, the potential damages and failures of the brake caliper component were initially evaluated through literature surveys and direct interviews with industry experts where two types of damages were identified, namely, cracks and broken or fractured parts. Then, the validation focuses on comparative analysis of two different conditions of the brake caliper housing: original, and repaired caliper model using finite element analysis in ANSYS. Results indicate that the strength of the repaired caliper model shows equal and higher strength compared with the original model. This result confirms that the repair process through AM can retain or improve the quality of the remanufactured brake caliper housing. Therefore, this paper provides a systematic framework for the evaluation of mechanical properties in multi-metal additive repair with the integration of failure analysis techniques.
期刊介绍:
The International Journal of Advanced Manufacturing Technology bridges the gap between pure research journals and the more practical publications on advanced manufacturing and systems. It therefore provides an outstanding forum for papers covering applications-based research topics relevant to manufacturing processes, machines and process integration.