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Dimensional and geometrical deviations of an assembly with a lattice structure manufactured by a material extrusion process: numerical and experimental results

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Abstract

During the additive manufacturing process, some geometrical deviations can arise, due to several thermomechanical phenomena that make residual stress rise. The study of dimensional and geometrical deviations connected with a manufacturing process is very important to achieve high-quality parts and to be able to assemble the obtained parts to arrive at assembly products with the desired functional requirements. This work aims to show a numerical procedure to predict the dimensional and geometrical deviations from the nominal of two parts in ABS material with a lattice structure inside an assembly that starts from the models of the parts obtained by simulating the material extrusion process. The idea is to control the volume of the lattice parts using the proposed measurement routines that take into account the surfaces of the lattice parts commonly used to couple them. Once virtually printed, the proposed numerical procedure converts each of the two parts constituting the assembly into a skin model shape representation to which least squares algorithms are applied to define dimensional and geometrical errors of the boundary surfaces of the part. The model was validated using a set of experimental tests; both the parts of the assembly were manufactured and their boundary surfaces were measured by a coordinate measuring machine. The obtained results were compared with those numerically obtained and a very good agreement was found.

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Acknowledgements

The authors are grateful to Eng. Luca Carmine Visco for supporting this work, Fablab of Ferentino to help with experimental validation, to Prof. Nabil Anwer for his contribution to defining the reference case study.

Funding

This work has been started, thanks to an Erasmus + Traineeship position and was funded by the Italian M.I.U.R. (Ministry of Instruction, University, and Technology Research).

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Authors and Affiliations

  1. Department of Civil and Mechanical Engineering, Università di Cassino e del Lazio Meridionale, via G. di Biasio 43, 03043, Cassino, FR, Italy

    Wilma Polini

  2. Teknocompositi S.R.L., Piedimonte San Germano, 03030, Cassino, Italy

    Andrea Corrado

Authors
  1. Wilma Polini
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Contributions

All authors contributed to the study’s conception and design. Material preparation, data collection, and analysis were performed by Andrea Corrado and Wilma Polini. The first draft of the manuscript was written by Wilma Polini, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Wilma Polini.

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Polini, W., Corrado, A. Dimensional and geometrical deviations of an assembly with a lattice structure manufactured by a material extrusion process: numerical and experimental results. Int J Adv Manuf Technol 127, 689–701 (2023). https://doi.org/10.1007/s00170-023-11579-8

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  • DOI: https://doi.org/10.1007/s00170-023-11579-8

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