Researcher:
Mustafa, Syed Shahid

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PhD Student

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Syed Shahid

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Mustafa

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Mustafa, Syed Shahid

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2020 - 20212

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Researcher Of Publications: search.filters.isAuthorOfPublication.a1aad8de-7080-46ef-a7f4-97bd34ef309b

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    A new model and direct slicer for lattice structures
    (Springer, 2021) N/A; N/A; Department of Mechanical Engineering; Mustafa, Syed Shahid; Lazoğlu, İsmail; PhD Student; Faculty Member; Department of Mechanical Engineering; Manufacturing and Automation Research Center (MARC); Graduate School of Sciences and Engineering; College of Engineering; N/A; 179391
    This paper presents a model for generating strut-based lattice structures using topology optimization and their efficient direct slicing. These structures exhibit better physical properties and can represent the partial densities at the macro-scale level, which often appear in designs based on topology optimization. The fabrication of such large member structures with intricate geometries is possible by the additive manufacturing technologies which offer design freedom to produce the optimized parts for engineering applications. However, these structures generate millions of planer manifolds describing the strut members and result in large data files, thus making conventional procedures in additive manufacturing highly ineffective. Therefore, the design process for such structures requires efficient data manipulation and storage of the lattice topology. In the current work, a mathematical model for the strut primitive which connects two nodes in a cell is developed. Based on the proposed strut model, a structural optimization formulation is presented for lattice structures design under volume fraction constraint. A matrix-oriented compact data structure to express the lattice topology and the direct slicing algorithm which makes queries on the proposed compact data structure is presented as part of this work. The slicing kernel has been tailored for parallel implementation to handle engineering-scale applications which often consist of structures over a million struts. The article is organized into the "Introduction" section explaining the requirement and the novelty of this work. Following which, the automated design framework based on topology optimization procedure for lattice structures is given. The mathematical derivations and data structure of the strut-based lattice will be explained and the operations on model data for the direct slicing procedure are elaborated. Numerical experiments verifying the proposed method will be presented toward the end.
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    A design framework for build process planning in DMLS
    (Springer Nature, 2020) Department of Mechanical Engineering; N/A; Lazoğlu, İsmail; Mustafa, Syed Shahid; Faculty Member; PhD Student; Department of Mechanical Engineering; College of Engineering; Graduate School of Sciences and Engineering; 179391; N/A
    Additive manufacturing (AM) of metal parts using the direct metal laser sintering (DMLS) process employs layer-wise melting of powder material to fabricate geometrically complex models. However, this option to build high-end metallic products comes with technical challenges, spreading along the overall process chain. Therefore, the powder bed fusion (PBF)-based metal-AM technology, such as DMLS, requires extensive research, addressing part quality and build repeatability issues, primarily induced by underlying thermal activity at the melt-pool level. At the same time, no software tool is available, beyond the commercial regime for the vital process planning of metal-AM using DMLS. This paper presents an open-source framework named MarcSLM, which integrates the thermally aware segmentation of the powder layer and build process control. First, a modular framework is proposed, based on metal-AM digital thread and then, its implementation is explained. The process starts with the preparation of a build platform, where multiple geometries are arranged with individualized process parameters. Afterwards, the laser exposure vectors are generated based on thermal region segmentation of sliced data. All the build data are packaged into a custom-build machine code, which is designed to derive the laser-galvanometer scanner duo as a synchronized entity and control the powder feedstock servomechanism. This article is organized into the introduction section explaining the requirement and the novelty of this research. Following which, the methodology and implementations are explained. The digital and experimental results verifying the proposed framework will be presented towards the end.