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研究生: Muhammad Rizwan ul Haq
Muhammad Rizwan ul Haq
論文名稱: 使用高速積層製造的波形彈簧設計、優化和分析
DESIGN, OPTIMIZATION, AND ANALYSIS OF WAVE SPRINGS USING HIGH-SPEED ADDITIVE MANUFACTURING
指導教授: 鄭正元
Jeng-Ywan Jeng
口試委員: 鄭正元
Jeng-Ywan Jeng
鄭逸琳
Zheng Yilin
林上智
Shang-Chih Lin
羅裕龍
Luo Yulong
鄭中緯
Zheng Zhongwei
覺元彙
Yuan-Hui Chueh
學位類別: 博士
Doctor
系所名稱: 工程學院 - 機械工程系
Department of Mechanical Engineering
論文出版年: 2022
畢業學年度: 110
語文別: 英文
論文頁數: 280
中文關鍵詞: 積層製造波形彈簧可變尺寸功能梯度WSdesign多功能中底多射流熔融三度週期最小曲面能量吸收承載力剛性疲勞
外文關鍵詞: Variable dimension, Functionally gradient, WSDesign, Midsole, MultiJet fusion, Triply periodic minimal surface (TPMS), Energy absorption, Load-bearing capacity, Stiffness, Fatigue.
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  • 科學與應用的研究透過複雜度、多樣性、優化設計以及改善機械性能,使其受到各行各業的青睞。螺旋型彈簧雖然受到許多限制,如製造技術、自由度的設計與統一規格,使其僅具有簡單的設計,但彈簧仍是解決工業問題不可或缺的角色。綜觀所有的彈簧皆是利用傳統製造程序進行生產,透過傳統製程無法製造具改善機械性能的幾何與尺寸多樣性設計,其中也包含了機械性能較為出色的波形彈簧。
    工業4.0與智能工業掀起了製造產業的革命,其加速了永續發展與結構輕量化的設計。根據工業4.0的特性將能源加工材料應用於製程使其創造綠色與零碳排放已成為工業界首要目標。波形彈簧憑藉著獨特的設計,相比於其他類型的彈簧具有更好的機械性能。根據文獻回顧鮮有積層製造研究與技術應用於波形彈簧。因此本研究將利用積層製造的特性進行多方面的探討,例如:複合設計、幾何尺寸、型態、線圈的截面變化等。
    本研究旨在使用積層製造技術設計接觸式、非接觸式波形彈簧、幾何與尺寸變化的複合設計,並針對不同的機械性能進行分析,並使用MultiJet Fusion技術(HP, 4200)進行3D列印,相較於其他積層製造技術是一種複合且快速的工藝。本研究基於實驗和模擬以驗證波形彈簧的機械性能,研究的最後選擇最佳設計進行進一步研究和優化,通過改變每個線圈的形態或厚度基於圓線與矩形扁平條帶線圈的互相結合,從而產生混合和功能梯度波形彈簧(FGWS),這些參數變化讓接觸式波形彈簧具有不同的機械性能。
    功能梯度波形彈簧設計應用於多功能中底的研究,整個中底由晶格結構組成,而在關鍵區域(足底壓力最高的區域如:腳跟、前腳掌和腳趾)使用波形彈簧。將設計的中底與市售的功能性金屬彈簧中底進行比較,發現使用積層製造的波形彈簧在能量吸收方面較好。此外波形彈簧設計需要專業的設計和建模知識,因為沒有專門設計波形彈簧的軟體,本研究亦開發了波形彈簧的數學設計模型,即 WSdesign,此模型的使用者透過直覺的圖形用戶界面定義每個設計參數,並生成可以直接列印或進一步分析的波形彈簧。
    此研究證明,積層製造的優勢可以很好的設計與製造複雜結構。根據此研究結果,具有可變尺寸和幾何形狀的接觸式波形彈簧能顯著改善的機械性能,另外帶狀形態已被證明是機械性能的關鍵因素,即扁平帶狀具有更好的承載能力,而圓線則增加了波形彈簧的能量吸收,相同地,每個線圈的波數、重疊和波高與承載能力、剛性和能量吸收成正比。相較於傳統的非接觸式金屬波形彈簧,聚合物接觸式波形彈簧表現出良好的疲勞和緩衝性能,這些特性提供了醫療和鞋類等行業能有更好且安全的選擇,因市售的彈簧多為金屬彈簧,這些金屬彈簧對人體具有不同形式的潛在危害。


    Scientific and application-based research has broadened its horizons by the addition of complex, intricate but optimized designs with improved mechanical properties which are beneficial to every industry. Springs such as helical type, although having simple designs due to various manufacturing constraints, limited design freedom, and customized setups, is an integral part of the solution to many industrial problems and fulfilling the industrial requirements. All springs including wave springs that are considered to have better mechanical properties than other types are manufactured by traditional manufacturing processes using customized machines. These fabrication units cannot manufacture complex designs having geometric and dimensional variations that can have improved mechanical properties.
    Industry 4.0 or smart industry is a revolution of manufacturing that addressed/improved many aspects including sustainability and light-weighting of the design/structure. It also leads to green and zero-carbon manufacturing i.e., the application of energy to process the material without emission of carbon which has become the prime objective of almost all industrial hubs. Wave springs have a unique and optimized design that has better mechanical properties than other types of springs. Based on the literature review, it was observed that there is hardly any research or attempts to manufacture wave springs using additive manufacturing. So, many aspects need to be addressed and explored such as complexity of design, geometric/dimensional variations, morphology, cross-sectional change of coils, etc. To fulfill these research gaps, it was imperative to design and manufacture wave springs using the design freedom of additive manufacturing.
    This study aims to design and additive manufacture (AM) contact and non-contact wave springs along with complex designs having geometric as well as dimensional variations and analyzed for different mechanical properties. All designs were printed using MultiJet fusion technology (HP, 4200) which is a hybrid and fast process as compared to other AM techniques. Both experimental and simulation-based studies were carried out to investigate and validate the mechanical properties of wave springs. Finally, the best designs were chosen for further studies and optimization. Several wave springs were designed by varying the morphology or thickness of each coil, also by the combination of round wire-based coils with rectangular flat strip-based coils resulting in hybrid and functionally gradient wave springs (FGWS). All these parametric changes resulted in contact wave springs with improved mechanical properties.
    FGWS were used for the application/case study of a multifunctional midsole that was designed to incorporate wave springs at the critical area i.e., highest plantar pressure areas (heel, forefoot, and toe) while the entire midsole was comprised of the lattice structure. The designed midsole was compared with commercially available spring-based functional midsoles in which metal springs were used for energy absorption. AM wave springs were found to be better in energy absorption and return than metal wave springs. Additionally, it was found that wave spring designing needs in-depth design knowledge and CAD modeling expertise as there was no direct algorithm/software to design wave springs. Hence, a study was conducted to mathematically design a process of wave spring in which an algorithm was developed i.e., WSDesign. It allows the user to define each parameter of the required wave spring design through a user-friendly GUI (graphical user interface), and generates the spring which can be printed directly or considered for further analysis.
    This research proved that additive manufacturing with its unlimited design freedom undoubtedly played an important part to design and manufacture complex structures which are almost impossible using traditional manufacturing processes with improved mechanical properties. It was concluded that additively manufactured contact wave springs with variable dimensions and geometric shapes have significantly improved mechanical properties. The strip morphology proved to be a key factor for the mechanical performance i.e., the flat strip exhibits better load-bearing capacity while round wire increases the energy absorption of the wave spring. Similarly, the number of waves per coil, overlapping, and wave height ha a direct proportion to load-bearing capacity, stiffness, and energy absorption. These polymeric contact wave springs also showed good fatigue and cushioning properties as compared to traditional non-contact metal wave springs. These improved properties made this a better and safe choice for different industries including medical and footwear as commercially available spring-based applications use metal springs which always have a potential hazard in different forms for the human body.

    TABLE OF CONTENTS ACKNOWLEDGEMENTS iv DEDICATION v ABSTRACT vi TABLE OF CONTENTS x LIST OF FIGURES xiii LIST OF TABLES xxv CHAPTER 1 INTRODUCTION 1 1.1 Overview 1 1.1 Motivation 2 1.2 Problem statement 3 1.3 Objectives 3 1.4 Thesis Organization 5 CHAPTER 2 LITERATURE REVIEW 6 2.1 Introduction to mechanical springs 6 2.2 Wave springs 8 2.2.1 Pateneted work of wave spring 11 2.2.2 Applications of wave springs 12 2.3 Additive manufacturing 14 2.3.1 Material jetting 18 2.3.2 MultiJet Fusion 21 2.3.3 Study of additively manufactured springs and their applications 25 CHAPTER 3 DESIGN FOR ADDITIVE MANUFACTURING OF WAVE SPRINGS 30 3.1 Types of wave springs 30 3.2 Terminologies used to design wave springs 31 3.3 Designing of different wave springs 32 3.3.1 Designing of non-contact wave spring 33 3.3.2 Designing of contact wave springs 34 3.3.3 Design of wave springs with the various geometric shapes 37 3.3.4 Designing of hybrid and graded wave springs 39 3.3.5 Designing of wave spring with parametric variations 44 3.4 Designing of multifunctional midsole incorporated with functionally graded wave springs 47 3.4.1 Measurement of plantar pressure using F-Scan system 48 3.4.2 Designing of functionally graded wave spring for shoe midsole 49 3.4.3 Designing the midsole 52 CHAPTER 4 MATERIALS AND METHODS 57 4.1 Materials 57 4.1.1 Polyamide 12 (PA 12) 58 4.1.2 Printed Material Properties 61 4.1.3 PLA plastic or polylactic acid 65 4.1.4 Thermoplastic polyurethane (TPU) 66 4.1.5 Resin material 66 4.2 Finite Element Analysis 67 4.2.1 FEA Solver 67 4.3 Manufacturing Strategy 74 4.3.1 HP MJF 4200 75 4.3.2 HP MJF 580 85 4.3.3 Selective laser sintering (SLS) 87 4.4 Experimental Testing 88 4.4.1 Dimensional Measurements 89 4.4.2 Calculation of compressible distance and strain endpoint 90 4.4.3 Uniaxial compression Testing (loading- unloading) 93 4.5 Result Calculations 94 CHAPTER 5 RESULTS AND DISCUSSION 96 5.1 Effect of geometric variation and morphology of strip coil of wave spring 96 5.1.1 Load bearing capacity/strength 96 5.1.2 Stress-strain analysis 102 5.1.3 Energy absorption 109 5.1.4 Stiffness 111 5.2 Effect of cross-sectional area and symmetrical variation of coil on the performance of wave springs 112 5.2.1 Strength of each design 113 5.2.2 Stress-strain analysis 117 5.2.3 Energy loss 118 5.2.4 Stiffness of each design 120 5.3 Effect of symmetrical variation on the performance of wave spring 121 5.3.1 Analysis through FEA 121 5.4 Analysis of parametric variation on the performance of wave springs 126 5.4.1 Load-bearing capacity 126 5.4.2 Energy absorption 141 5.4.3 Stiffness 143 5.5 Case Study: Analysis of Multifunctional Midsole 144 5.5.1 Load bearing capacity/strength of functionally graded wave springs 145 5.5.2 Energy absorption 152 5.5.3 Stiffness of each wave spring 154 5.6 Evaluation of wave springs integrated with EVA foam 155 5.6.1 Load- compression response 156 5.6.2 Energy absorption/loss 158 5.7 Performance comparison of metal and polymer wave spring 159 5.7.1 Prolonged loading-unloading testing 162 5.8 Performance checks of complete multifunctional midsole 163 5.8.1 Load-bearing capacity of midsole through Homogenization 163 5.8.2 Strength of midsole 165 5.9 Comparison: multifunctional midsole with commercially available spring structure-based midsoles 166 5.10 Limitations for AM designed multifunctional midsole 168 CHAPTER 6 WSdesign: ALGORITHM FOR GENERATING WAVE SPRINGS 170 6.1 Introduction 171 6.2 The manual procedure of wave spring design 175 6.3 Methodology 176 6.3.1 Development of WSdesign Platform 178 6.4 Validation 183 6.5 Research and industrial impact 186 CHAPTER 7 CONCLUSION AND FUTURE WORK 188 7.1 Conclusions 190 7.2 Future work 194 REFERENCES 196 APPENDIX I 208 APPENDIX II 213 APPENDIX III 215

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