This page has only limited features, please log in for full access.
The interest in additive manufacturing (AM) processes is constantly increasing due to the many advantages they offer. To this end, a variety of modelling techniques for the plethora of the AM mechanisms has been proposed. However, the process modelling complexity, a term that can be used in order to define the level of detail of the simulations, has not been clearly addressed so far. In particular, one important aspect that is common in all the AM processes is the movement of the head, which directly affects part quality and build time. The knowledge of the entire progression of the phenomenon is a key aspect for the optimization of the path as well as the speed evolution in time of the head. In this study, a metamodeling framework for AM is presented, aiming to increase the practicality of simulations that investigate the effect of the movement of the head on part quality. The existing AM process groups have been classified based on three parameters/axes: temperature of the process, complexity, and part size, where the complexity has been modelled using a dedicated heuristic metric, based on entropy. To achieve this, a discretized version of the processes implicated variables has been developed, introducing three types of variable: process parameters, key modeling variables and performance indicators. This can lead to an enhanced roadmap for the significance of the variables and the interpretation and use of the various models. The utilized spectrum of AM processes is discussed with respect to the modelling types, namely theoretical/computational and experimental/empirical.
Panagiotis Stavropoulos; Panagis Foteinopoulos; Alexios Papapacharalampopoulos. On the Impact of Additive Manufacturing Processes Complexity on Modelling. Applied Sciences 2021, 11, 7743 .
AMA StylePanagiotis Stavropoulos, Panagis Foteinopoulos, Alexios Papapacharalampopoulos. On the Impact of Additive Manufacturing Processes Complexity on Modelling. Applied Sciences. 2021; 11 (16):7743.
Chicago/Turabian StylePanagiotis Stavropoulos; Panagis Foteinopoulos; Alexios Papapacharalampopoulos. 2021. "On the Impact of Additive Manufacturing Processes Complexity on Modelling." Applied Sciences 11, no. 16: 7743.
Integrating a manufacturing process is not a straightforward decision. Involved cost models are complex covering the whole lifecycle of the part in the context of circular economy. In this work, given the complexity of circular industry and the modularity required in the case of electric vehicles, a framework for a dedicated decision support system is presented. A case study for a microfactory is presented. The two stages of the decision-support system (DSS) are applied, with the first one proving empirically the feasibility of the technology integration and the second one involving a detailed cost model for assessment of the return of investment (ROI).
P. Stavropoulos; A. Papacharalampopoulos; C. Michail; V. Vassilopoulos; K. Alexopoulos; Pietro Perlo. A two-stage decision support system for manufacturing processes integration in microfactories for electric vehicles. Procedia Manufacturing 2021, 54, 106 -111.
AMA StyleP. Stavropoulos, A. Papacharalampopoulos, C. Michail, V. Vassilopoulos, K. Alexopoulos, Pietro Perlo. A two-stage decision support system for manufacturing processes integration in microfactories for electric vehicles. Procedia Manufacturing. 2021; 54 ():106-111.
Chicago/Turabian StyleP. Stavropoulos; A. Papacharalampopoulos; C. Michail; V. Vassilopoulos; K. Alexopoulos; Pietro Perlo. 2021. "A two-stage decision support system for manufacturing processes integration in microfactories for electric vehicles." Procedia Manufacturing 54, no. : 106-111.
In an ever-increasing competitiveness in the engineering landscape, increased complexity of products and processes and reduction of time-to market for products are key competitive factors. To this end, engineers seek the most efficient utilization of digital tools, such as Computer-Aided (CAx), to enable virtual prototyping and reduce the time invested in physical testing of a system after it is built. However, the introduction of digital tools in the development process cannot guarantee a successful design on its own and requires effective utilization of these tools from the engineer, in the form of modeling the system, selecting the optimal compromise in detail to reduce the complexity of the model and interpretation of results. In this study, the virtual prototyping of a cryogenic cooling system for hybrid manufacturing is investigated. Hybrid manufacturing, incorporating additive and subtractive capabilities in the same machine tool, is one of the most promising technologies that can ramp up the use of Additive Manufacturing in many high-value industrial components. The use of cryogenic cooling is a sustainable alternative to conventional emulsion cooling, which can have detrimental effects on the part and machine tool components, without compromising the heat dissipation performance. The paper presents the design considerations during the conceptual design phase, the design variables to be investigated for the parametric design phase are selected, a physics-based model is utilized for the virtual optimization of the design and the results are interpreted and discussed.
Panagiotis Stavropoulos; Thanassis Souflas; Nikolas Porevopoulos; Harry Bikas. Application of virtual engineering tools to support design optimization: a case study on a cryogenic machining system. Procedia CIRP 2021, 100, 181 -186.
AMA StylePanagiotis Stavropoulos, Thanassis Souflas, Nikolas Porevopoulos, Harry Bikas. Application of virtual engineering tools to support design optimization: a case study on a cryogenic machining system. Procedia CIRP. 2021; 100 ():181-186.
Chicago/Turabian StylePanagiotis Stavropoulos; Thanassis Souflas; Nikolas Porevopoulos; Harry Bikas. 2021. "Application of virtual engineering tools to support design optimization: a case study on a cryogenic machining system." Procedia CIRP 100, no. : 181-186.
Manufacturing process design and implementation can benefit from the adaptation of Digital Twins. However, the explanatory power coming by physics models presents a strong contradiction with the demand of rapid decision making required for their control and optimization. In the context of laser welding applications, this work investigates three physics-based modelling methods (namely direct Stefan method, apparent heat capacity method and Enthalpy method) along with sensorial data towards the formation of a knowledge database in order to aid the development of a Digital Twin. Also, the methodology for creating such a Digital Twin is discussed incorporating the best result(s) and method(s). This Digital Twin is proved useful in optimizing the process itself but also monitoring, through selection of sensors.
Alexios Papacharalampopoulos; Kyriakos Sabatakakis; Panos Stavropoulos. Incorporating process physics phenomena in formation of digital twins: laser welding case. Procedia CIRP 2021, 99, 490 -495.
AMA StyleAlexios Papacharalampopoulos, Kyriakos Sabatakakis, Panos Stavropoulos. Incorporating process physics phenomena in formation of digital twins: laser welding case. Procedia CIRP. 2021; 99 ():490-495.
Chicago/Turabian StyleAlexios Papacharalampopoulos; Kyriakos Sabatakakis; Panos Stavropoulos. 2021. "Incorporating process physics phenomena in formation of digital twins: laser welding case." Procedia CIRP 99, no. : 490-495.
The additive manufacturing process control utilizing digital twins is an emerging issue. However, robustness in process performance is still an open aspect, due to uncertainties, e.g., in material properties. To this end, in this work, a digital twin offering uncertainty management and robust process control is designed and implemented. As a process control design method, the Linear Matrix Inequalities are adopted. Within specific uncertainty limits, the performance of the process is proven to be acceptably constant, thus achieving robust additive manufacturing. Variations of the control law are also investigated, in order for the applicability of the control to be demonstrated in different machine architectures. The comparison of proposed controllers is done against a fine-tuned conventional proportional–integral–derivative (PID) and the initial open-loop model for metals manufacturing. As expected, the robust control design achieved a 68% faster response in the settling time metric, while a well-calibrated PID only achieved 38% compared to the initial model.
Panagiotis Stavropoulos; Alexios Papacharalampopoulos; Christos Michail; George Chryssolouris. Robust Additive Manufacturing Performance through a Control Oriented Digital Twin. Metals 2021, 11, 708 .
AMA StylePanagiotis Stavropoulos, Alexios Papacharalampopoulos, Christos Michail, George Chryssolouris. Robust Additive Manufacturing Performance through a Control Oriented Digital Twin. Metals. 2021; 11 (5):708.
Chicago/Turabian StylePanagiotis Stavropoulos; Alexios Papacharalampopoulos; Christos Michail; George Chryssolouris. 2021. "Robust Additive Manufacturing Performance through a Control Oriented Digital Twin." Metals 11, no. 5: 708.
Additive manufacturing (AM) provides great new possibilities concerning designing. AM turns to free-form designs with reduced weight, which are individually customized. Taking advantage of these aspects, the manufacturing world is led to a still not fully discovered, continuously expanding, era. This study includes a thorough look of a designing process for AM; starting from a theoretical design and its parameters to a more efficient CAD model, intended to be used for the final product. The main goal of this, process-planning driven, project has been the construction of a plastic panel as a decorative part of a mobility platform with the minimum use of support structure. Manufacturability analysis, that followed the CAD modeling process, required the definition of the most influential parameters, such as infill percentage, material and built orientation. The constant re-definition of the parameters, in order to minimize the necessity of a support structure, completed the final CAD model. The results of this procedure form a concise list of the challenges, one faces during the designing for an AM product, but also fulfills the requirements for a fully functional panel used as a vehicle part.
Aggeliki Karapiperi; Lydia Athanasopoulou; Alexios Papacharalampopoulos; Panos Stavropoulos. Parametric design for 3D printed plastic panel as a decorative part of a mobility platform. Procedia CIRP 2021, 97, 81 -86.
AMA StyleAggeliki Karapiperi, Lydia Athanasopoulou, Alexios Papacharalampopoulos, Panos Stavropoulos. Parametric design for 3D printed plastic panel as a decorative part of a mobility platform. Procedia CIRP. 2021; 97 ():81-86.
Chicago/Turabian StyleAggeliki Karapiperi; Lydia Athanasopoulou; Alexios Papacharalampopoulos; Panos Stavropoulos. 2021. "Parametric design for 3D printed plastic panel as a decorative part of a mobility platform." Procedia CIRP 97, no. : 81-86.
Concrete hybrid manufacturing is an emerging technology for the construction industry sector. Herein, an innovative construction machine based on a cable robot, which is able to carry additive and material removal modules is presented and the challenges for its assembly are given. The robots’ motion along with the finished part quality are discussed. The information management system including BIM, path planning and control is explored and presented. In addition, material challenges and corresponding approaches are given. Finally, building parts are illustrated and the overall performance in terms of parts quality and machine lifecycle is discussed. © 2020 The Authors, Published by Elsevier B.V. Peer review under the responsibility of the scientific committee of CIRP
Manuel Menendez Muñiz; Marjorie Chantin; Cristian Raul Vintila; Marc Fabritius; Christoph Martin; Laura Calvo; Louison Poudelet; Joseph Canou; Maylis Uhart; Alexios Papacharalampopoulos; Panos Stavropoulos; Nils Olof Emanuel Olsson; José Antonio Tenorio; Javier Alonso Madrid; Justin Dirrenberger; Ivan Muñoz. Concrete hybrid manufacturing: A machine architecture. Procedia CIRP 2021, 97, 51 -58.
AMA StyleManuel Menendez Muñiz, Marjorie Chantin, Cristian Raul Vintila, Marc Fabritius, Christoph Martin, Laura Calvo, Louison Poudelet, Joseph Canou, Maylis Uhart, Alexios Papacharalampopoulos, Panos Stavropoulos, Nils Olof Emanuel Olsson, José Antonio Tenorio, Javier Alonso Madrid, Justin Dirrenberger, Ivan Muñoz. Concrete hybrid manufacturing: A machine architecture. Procedia CIRP. 2021; 97 ():51-58.
Chicago/Turabian StyleManuel Menendez Muñiz; Marjorie Chantin; Cristian Raul Vintila; Marc Fabritius; Christoph Martin; Laura Calvo; Louison Poudelet; Joseph Canou; Maylis Uhart; Alexios Papacharalampopoulos; Panos Stavropoulos; Nils Olof Emanuel Olsson; José Antonio Tenorio; Javier Alonso Madrid; Justin Dirrenberger; Ivan Muñoz. 2021. "Concrete hybrid manufacturing: A machine architecture." Procedia CIRP 97, no. : 51-58.
The goal of this work is to parametrically design an affordable platform attachable to a wheelchair offering autonomous guidance to people with disabilities. Special focus is given on manufacturability and assemble-ability of the platform. This mobility platform consists of a number of modules, most of which are expected to be manufactured utilizing AM technologies. Moving into the humanitarian engineering domain, under the prism of customization / personalization, the main objective is to offer different variants of assembled platforms. To this end, a well-defined parametric design flow has been utilized followed by a manufacturability analysis. This procedure helps defining what variant should be used as per the requirements presumed and what modules are going to be used in each case. Furthermore, parameters of the modules themselves can be chosen based on the usability. Such parameters include the infill of the modules and their dimensions. © 2020 The Authors, Published by Elsevier B.V. Peer review under the responsibility of the scientific committee of CIRP.
Alexios Papacharalampopoulos; Angeliki Karapiperi; Panos Stavropoulos. Humanitarian engineering design methodology for AM metallic products: A smart mobility platform case. Procedia CIRP 2021, 97, 59 -65.
AMA StyleAlexios Papacharalampopoulos, Angeliki Karapiperi, Panos Stavropoulos. Humanitarian engineering design methodology for AM metallic products: A smart mobility platform case. Procedia CIRP. 2021; 97 ():59-65.
Chicago/Turabian StyleAlexios Papacharalampopoulos; Angeliki Karapiperi; Panos Stavropoulos. 2021. "Humanitarian engineering design methodology for AM metallic products: A smart mobility platform case." Procedia CIRP 97, no. : 59-65.
Manufacturing process related functionalities, like optimization and control, are in general demanding in terms of data, computational time and efficiency. However, there are no generic certification or validation schemes that can be followed. In particular, only ISO application can verify the suitability of operations up to an extent. The current work utilizes an enhanced version of Blockchain so that functionalities at the process level can be certified as per a particular scheme. The concept of ledger is elaborated to this end, to manipulate knowledge and be able to handle it like an asset that is exchanged. Thus, a specific generic framework is proposed, herein, to reassure that the right kind of information has been exchanged during process control and optimization. Furthermore, expert distributed agents are utilized to turn knowledge into certified procedures. Encryption issues are also regarded, providing safety and security as extra characteristics. The case study of thermal process control is regarded in this sense to prove the complementary character of these concepts and the usability of the framework. Finally, the existence of additional features within this loop is discussed, like the validation of quantifying concepts like resource streams.
Alexios Papacharalampopoulos; Harry Bikas; Christos Michail; Panagiotis Stavropoulos. On the generation of validated manufacturing process optimization and control schemes. Procedia CIRP 2021, 96, 57 -62.
AMA StyleAlexios Papacharalampopoulos, Harry Bikas, Christos Michail, Panagiotis Stavropoulos. On the generation of validated manufacturing process optimization and control schemes. Procedia CIRP. 2021; 96 ():57-62.
Chicago/Turabian StyleAlexios Papacharalampopoulos; Harry Bikas; Christos Michail; Panagiotis Stavropoulos. 2021. "On the generation of validated manufacturing process optimization and control schemes." Procedia CIRP 96, no. : 57-62.
Concrete based Additive Manufacturing (AM) is an emerging technological sector including numerous potential application fields, varying from buildings to facades and furniture. Path planning optimization of Concrete based AM is considered as a milestone, towards further automation and utilization of the technology. The current study presents a modular framework for the holistic multi-level optimization of path planning for concrete AM. Steps are described in detail and include strategies for the selection of a near optimum path and selection of acceptable process parameters, along with controlling actions of a cable robot based concrete AM process head. Also, following outcomes derived from the path strategy, an appropriate building block geometry is generated through design successive approximations. These building blocks fulfil (mechanical and thermal) functional requirements as well as they meet buildability criteria, with emphasis on minimizing idle times. Finally, a software platform supporting the aforementioned activities has been implemented and is presented herein. It provides an interface based on Web-Services, achieving portability of data and functionalities.
A. Papacharalampopoulos; H. Bikas; P. Foteinopoulos; P. Stavropoulos. A Path Planning Optimization Framework for Concrete Based Additive Manufacturing Processes. Procedia Manufacturing 2020, 51, 649 -654.
AMA StyleA. Papacharalampopoulos, H. Bikas, P. Foteinopoulos, P. Stavropoulos. A Path Planning Optimization Framework for Concrete Based Additive Manufacturing Processes. Procedia Manufacturing. 2020; 51 ():649-654.
Chicago/Turabian StyleA. Papacharalampopoulos; H. Bikas; P. Foteinopoulos; P. Stavropoulos. 2020. "A Path Planning Optimization Framework for Concrete Based Additive Manufacturing Processes." Procedia Manufacturing 51, no. : 649-654.
A smart mobility platform aiding in guidance of disabled people is a concept that can facilitate people’s everyday life. However, design and manufacturing of such a system faces many issues in terms of agility in design, implementation and usability verification. To this end, the concept of Product-Service System (PSS) seems to be the solution; being an emerging concept oriented towards the dematerialisation of the economy, meeting also the requirement of manufacturing industries to cope with the radical changes in the global market. In this study, the development of a context awareness and path planning system under the prism of PSSs is examined. This module is considered to be promoted as a pay per service unit that can be implemented in different operational scenarios and environments. The key objective is to deliver the obstacle avoidance and path planning functionality and add value to the customer, but at the same keep the production lean and flexible. To this end, Round Robin parts are presented, taking into account mounts and jigs for controllers dealing with supervised machine learning techniques and path planning, light-weight system-of-sensors and structural integrity of the module. The concept evaluation is outlined through a case study based on the integration of the system in a smart mobility platform to provide autonomous mobility. The mobility platform is expected to operate within a predefined area, characterized by a complex environment.
L. Athanasopoulou; A. Papacharalampopoulos; P. Stavropoulos; D. Mourtzis. Design and manufacturing of a smart mobility platform’s context awareness and path planning module: A PSS approach. Procedia Manufacturing 2020, 51, 61 -66.
AMA StyleL. Athanasopoulou, A. Papacharalampopoulos, P. Stavropoulos, D. Mourtzis. Design and manufacturing of a smart mobility platform’s context awareness and path planning module: A PSS approach. Procedia Manufacturing. 2020; 51 ():61-66.
Chicago/Turabian StyleL. Athanasopoulou; A. Papacharalampopoulos; P. Stavropoulos; D. Mourtzis. 2020. "Design and manufacturing of a smart mobility platform’s context awareness and path planning module: A PSS approach." Procedia Manufacturing 51, no. : 61-66.
Hybrid process chains lack structured decision-making tools to support advanced manufacturing strategies, consisting of a simulation-enhanced sequencing and planning of additive and subtractive processes. The paper sets out a method aiming at identifying an optimal process window for additive manufacturing, while considering its integration with conventional technologies, starting from part inspection as a built-in functionality, quantifying geometrical and dimensional part deviations, and triggering an effective hybrid process recipe. The method is demonstrated on a hybrid manufacturing scenario, by dynamically sequencing laser deposition (DLM) and subtraction (milling), triggered by intermediate inspection steps to ensure consistent growth of a part.
Panagiotis Stavropoulos; Harry Bikas; Oliver Avram; Anna Valente; George Chryssolouris. Hybrid subtractive–additive manufacturing processes for high value-added metal components. The International Journal of Advanced Manufacturing Technology 2020, 111, 645 -655.
AMA StylePanagiotis Stavropoulos, Harry Bikas, Oliver Avram, Anna Valente, George Chryssolouris. Hybrid subtractive–additive manufacturing processes for high value-added metal components. The International Journal of Advanced Manufacturing Technology. 2020; 111 (3-4):645-655.
Chicago/Turabian StylePanagiotis Stavropoulos; Harry Bikas; Oliver Avram; Anna Valente; George Chryssolouris. 2020. "Hybrid subtractive–additive manufacturing processes for high value-added metal components." The International Journal of Advanced Manufacturing Technology 111, no. 3-4: 645-655.
Vision technologies are used in both industrial and smart city applications in order to provide advanced value products due to embedded self-monitoring and assessment services. In addition, for the full utilization of the obtained data, deep learning is now suggested for use. To this end, the current work presents the implementation of image recognition techniques alongside the original the quality assessment of a Parabolic Trough Collector (PTC) reflector surface to locate and identify surface irregularities by classifying images as either acceptable or non-acceptable. The method consists of a three-step solution that promotes an affordable implementation in a relatively small time period. More specifically, a 3D Computer Aided Design (CAD ) of the PTC was used for the pre-training of neural networks, while an aluminum reflector surface was used to verify algorithm performance. The results are promising, as this method proved applicable in cases where the actual part was manufactured in small batches or under the concept of customized manufacturing. Consequently, the algorithm is capable of being trained with a limited number of data.
Alexios Papacharalampopoulos; Konstantinos Tzimanis; Kyriakos Sabatakakis; Panagiotis Stavropoulos. Deep Quality Assessment of a Solar Reflector Based on Synthetic Data: Detecting Surficial Defects from Manufacturing and Use Phase. Sensors 2020, 20, 5481 .
AMA StyleAlexios Papacharalampopoulos, Konstantinos Tzimanis, Kyriakos Sabatakakis, Panagiotis Stavropoulos. Deep Quality Assessment of a Solar Reflector Based on Synthetic Data: Detecting Surficial Defects from Manufacturing and Use Phase. Sensors. 2020; 20 (19):5481.
Chicago/Turabian StyleAlexios Papacharalampopoulos; Konstantinos Tzimanis; Kyriakos Sabatakakis; Panagiotis Stavropoulos. 2020. "Deep Quality Assessment of a Solar Reflector Based on Synthetic Data: Detecting Surficial Defects from Manufacturing and Use Phase." Sensors 20, no. 19: 5481.
An analysis related to the defect detection on a rubber weather-strip extrusion production line is presented herein. A vision system has been developed to evaluate the products quality in terms of dimensional accuracy. As a first method, the extrudate’s dimensions were identified by making use of image processing algorithms for detecting the edge and classifying the results. Furthermore, neural networks were used for identifying the dimensional patterns and classifying the profiles. Both methods have been proved to be accurate and repeatable. The study’s results show high potential for application in manufacturing environments due to models the high processing speed capabilities.
Panagiotis Stavropoulos; Alexios Papacharalampopoulos; Dimitris Petridis. A vision-based system for real-time defect detection: a rubber compound part case study. Procedia CIRP 2020, 93, 1230 -1235.
AMA StylePanagiotis Stavropoulos, Alexios Papacharalampopoulos, Dimitris Petridis. A vision-based system for real-time defect detection: a rubber compound part case study. Procedia CIRP. 2020; 93 ():1230-1235.
Chicago/Turabian StylePanagiotis Stavropoulos; Alexios Papacharalampopoulos; Dimitris Petridis. 2020. "A vision-based system for real-time defect detection: a rubber compound part case study." Procedia CIRP 93, no. : 1230-1235.
This paper presents an experimental investigation of rubber material quality during extrusion phase utilizing vibrational testing. An attempt to classify rubber profile samples including two kinds of defects (material based and geometrical), based on the response acquired from vibration test is presented. An experimental apparatus has been built for the purposes of this work. Vibrational signals were captured through a series of experiments and signal processing methods have been used for analysing the captured signals. The investigation revealed that the samples could be classified according to their quality characteristics.
Alexios Papacharalampopoulos; Demitris Petridis; Panos Stavropoulos. Experimental Investigation of rubber extrusion process through vibrational testing. Procedia CIRP 2020, 93, 1236 -1240.
AMA StyleAlexios Papacharalampopoulos, Demitris Petridis, Panos Stavropoulos. Experimental Investigation of rubber extrusion process through vibrational testing. Procedia CIRP. 2020; 93 ():1236-1240.
Chicago/Turabian StyleAlexios Papacharalampopoulos; Demitris Petridis; Panos Stavropoulos. 2020. "Experimental Investigation of rubber extrusion process through vibrational testing." Procedia CIRP 93, no. : 1236-1240.
Diagnosis systems for laser processing are being integrated into industry. However, their readiness level is still questionable under the prism of the Industry’s 4.0 design principles for interoperability and intuitive technical assistance. This paper presents a novel multifunctional, web-based, real-time quality diagnosis platform, in the context of a laser welding application, fused with decision support, data visualization, storing, and post-processing functionalities. The platform’s core considers a quality assessment module, based upon a three-stage method which utilizes feature extraction and machine learning techniques for weld defect detection and quality prediction. A multisensorial configuration streams image data from the weld pool to the module in which a statistical and geometrical method is applied for selecting the input features for the classification model. A Hidden Markov Model is then used to fuse this information with earlier results for a decision to be made on the basis of maximum likelihood. The outcome is fed through web services in a tailored User Interface. The platform’s operation has been validated with real data.
Panagiotis Stavropoulos; Alexios Papacharalampopoulos; John Stavridis; Kyriakos Sampatakakis. A three-stage quality diagnosis platform for laser-based manufacturing processes. The International Journal of Advanced Manufacturing Technology 2020, 110, 2991 -3003.
AMA StylePanagiotis Stavropoulos, Alexios Papacharalampopoulos, John Stavridis, Kyriakos Sampatakakis. A three-stage quality diagnosis platform for laser-based manufacturing processes. The International Journal of Advanced Manufacturing Technology. 2020; 110 (11-12):2991-3003.
Chicago/Turabian StylePanagiotis Stavropoulos; Alexios Papacharalampopoulos; John Stavridis; Kyriakos Sampatakakis. 2020. "A three-stage quality diagnosis platform for laser-based manufacturing processes." The International Journal of Advanced Manufacturing Technology 110, no. 11-12: 2991-3003.
The current exponential increasement of the market size and the Technology Readiness Level (TRL) of Additive Manufacturing (AM) technologies has only been met with a linear increment of additively manufactured components and final products. The causality of this inconsistency is traced to the lack of expertise knowledge, methodologies for technological assessment and design for AM that render the AM processes’ competitiveness unattractive for the industrial sectors. The need to determine the added value of an AM technology for implementation to the manufacturing phases of an entity is of the essence. This work proposes an assessment method to screen the added value that an AM technology can offer to an entity by quantifying the AM utilization throughout the different product development and production stages. To quantify the AM technology assessment in terms of: final part manufacturing, flexibility to the production line, input to the engineering and design stages, cost reduction and increased performance of the final part; two already existing metrics were used (TRL and MRL), three were introduced (UPD, UFP and PPP) and the unified AM Manufacturability Assessment (AMMA) equation was created to combine the previous. The proposed method is to improve the AM industrial uptake and steer the community towards an enhanced Design for AM mentality.
Andreas K. Lianos; Sotiris Koutsoukos; Harry Bikas; Panagiotis Stavropoulos. Manufacturability Assessment and Design for AM. Procedia CIRP 2020, 91, 290 -294.
AMA StyleAndreas K. Lianos, Sotiris Koutsoukos, Harry Bikas, Panagiotis Stavropoulos. Manufacturability Assessment and Design for AM. Procedia CIRP. 2020; 91 ():290-294.
Chicago/Turabian StyleAndreas K. Lianos; Sotiris Koutsoukos; Harry Bikas; Panagiotis Stavropoulos. 2020. "Manufacturability Assessment and Design for AM." Procedia CIRP 91, no. : 290-294.
The design methodologies and part shape algorithms for additive manufacturing (AM) are rapidly growing fields, proven to be of critical importance for the uptake of additive manufacturing of parts with enhanced performance in all major industrial sectors. The current trend for part design is a computationally driven approach where the parts are algorithmically morphed to meet the functional requirements with optimized performance in terms of material distribution. However, the manufacturability restrictions of AM processes are not considered at the primary design phases but at a later post-morphed stage of the part’s design. This paper proposes an AM design method to ensure: (1) optimized material distribution based on the load case and (2) the part’s manufacturability. The buildability restrictions from the direct energy deposition (DED) AM technology were used as input to the AM shaping algorithm to grant high AM manufacturability. The first step of this work was to define the term of AM manufacturability, its effect on AM production, and to propose a framework to estimate the quantified value of AM manufacturability for the given part design. Moreover, an AM design method is proposed, based on the developed internal stresses of the build volume for the load case. Stress tensors are used for the determination of the build orientation and as input for the part morphing. A top-down mesoscale geometric optimization is used to realize the AM part design. The DED Design for Additive Manufacturing (DfAM) rules are used to delimitate the morphing of the part, representing at the same time the freeform mindset of the AM technology. The morphed shape of the part is optimized in terms of topology and AM manufacturability. The topology optimization and AM manufacturability indicator (TMI) is introduced to screen the percentage of design elements that serve topology optimization and the ones that serve AM manufacturability. In the end, a case study for proof of concept is realized.
Andreas K. Lianos; Harry Bikas; Panagiotis Stavropoulos. A Shape Optimization Method for Part Design Derived from the Buildability Restrictions of the Directed Energy Deposition Additive Manufacturing Process. Designs 2020, 4, 19 .
AMA StyleAndreas K. Lianos, Harry Bikas, Panagiotis Stavropoulos. A Shape Optimization Method for Part Design Derived from the Buildability Restrictions of the Directed Energy Deposition Additive Manufacturing Process. Designs. 2020; 4 (3):19.
Chicago/Turabian StyleAndreas K. Lianos; Harry Bikas; Panagiotis Stavropoulos. 2020. "A Shape Optimization Method for Part Design Derived from the Buildability Restrictions of the Directed Energy Deposition Additive Manufacturing Process." Designs 4, no. 3: 19.
Panagis Foteinopoulos; Alexios Papacharalampopoulos; Konstantinos Angelopoulos; Panagiotis Stavropoulos. Development of a simulation approach for laser powder bed fusion based on scanning strategy selection. The International Journal of Advanced Manufacturing Technology 2020, 108, 3085 -3100.
AMA StylePanagis Foteinopoulos, Alexios Papacharalampopoulos, Konstantinos Angelopoulos, Panagiotis Stavropoulos. Development of a simulation approach for laser powder bed fusion based on scanning strategy selection. The International Journal of Advanced Manufacturing Technology. 2020; 108 (9-10):3085-3100.
Chicago/Turabian StylePanagis Foteinopoulos; Alexios Papacharalampopoulos; Konstantinos Angelopoulos; Panagiotis Stavropoulos. 2020. "Development of a simulation approach for laser powder bed fusion based on scanning strategy selection." The International Journal of Advanced Manufacturing Technology 108, no. 9-10: 3085-3100.
Optimization and control of Manufacturing Processes seem to be the key-enabling approaches towards Efficient Manufacturing and Zero-defect. Thus, it is of high importance to study what-if scenarios regarding changes of Process Parameters. To achieve this in real time, Digital Twins have to be designed and implemented. Towards this end, in the current work, a specific methodology, originating from process physics is reviewed as a candidate technology for the process level Digital Twin. The requirements are stated and checked one-to-one and respective numerical results are shown. Discussion on Zero-defect and optimization under the prism of Industry 4.0 is presented
Alexios Papacharalampopoulos; Panagiotis Stavropoulos; Demetris Petrides. Towards a digital twin for manufacturing processes: applicability on laser welding. Procedia CIRP 2020, 88, 110 -115.
AMA StyleAlexios Papacharalampopoulos, Panagiotis Stavropoulos, Demetris Petrides. Towards a digital twin for manufacturing processes: applicability on laser welding. Procedia CIRP. 2020; 88 ():110-115.
Chicago/Turabian StyleAlexios Papacharalampopoulos; Panagiotis Stavropoulos; Demetris Petrides. 2020. "Towards a digital twin for manufacturing processes: applicability on laser welding." Procedia CIRP 88, no. : 110-115.