The advancement of 3D printing technology has been remarkable, yet the quality of printed prototypes heavily relies on the rheological behavior of the materials used. This study focuses on optimizing geopolymer-based composite formulas to achieve high-quality 3D printing, with particular attention given to rheological analysis. Three metakaolins, Argical M1200s, Metamax, and Tempozz M88, were used as alumino-silicate precursors for the preparation of the geopolymer binders. Rheological studies were conducted on viscosity, shear stress, and responses to oscillations in amplitude and frequency. The Tempozz M88-based binder was identified as the most effective for the extrusion due to its optimal rheological properties. Subsequently, the study investigated the influence of the amount, up to 55%, and morphology of the fillers, comprising feldspar and wollastonite, on the rheology of the pastes. Also, the addition of Xanthan gum, a gelling agent in the geopolymer paste, was analyzed, revealing improved extrusion quality and more stable bead structures. Finally, a comprehensive comparison was carried out between two formulations chosen according to rheological observations, utilizing image sequences captured during 3D printing. This comparison highlighted the formulation that ensures structural stability, design accuracy, and minimized sagging. This study underscores the significance of geopolymer formula optimization, leveraging rheology as a pivotal tool to enhance 3D printing quality, thereby facilitating more precise and reliable applications of additive manufacturing.

In this paper we investigate the elastohydrodynamic (EHD) lubrication in ball bearings by means of a digital twin. Based on an original description involving the discrete element method (DEM), the digital twin integrates all the components of ball bearings and enables realistic behavior under mechanical loading and kinematic conditions. In order to check the standard indicators recommended by most ball bearing manufactures, a stiffness model for elliptical Hertzian contact and an improved EHD formulation for lubricated contact are implemented in the numerical tool. In addition, we have introduced into the discrete modeling an electrical capacitance model correlated to the fluid film thickness and the contact pressure. The numerical predictions of lubricant film capacitance provided by digital twin are in good accordance, both qualitatively and quantitatively, with the experimental data available in the literature. The coupling of the discrete method with the electrical approach enables efficient solutions to be provided in terms of lubrication regime in relation to the lubricant properties to optimize the bearing lifetime.

This paper deals with an efficient 3D modelling of a radial ball bearing to predict the operating lubrication regime under mechanical loading and mounting conditions by using the Discrete Element Method (DEM). Due to the relevance of such an approach, especially for multicontact systems, the lubrication regime associated with specific operating conditions can be predicted accurately. By means of an elastohydrodynamic lubrication formulation depending on parameters related to the size of contact area, mechanical properties of materials, roughness and fluid viscosity, the lubricant film thickness is predicted and used to take into consideration the fluid film damping effect and friction coefficient variation. The lubrication regime can be identified according to Stribeck curve with the assumption of a piezo-viscous-elastic behaviour of the lubricant. The numerical simulations performed with MULTICOR-3D software on an operating ball bearing shown that the lubrication regime at the rolling element-raceway contact can be easily monitored and quantitatively identified. To assess the efficiency of the discrete modelling, a parametric study is carried out in order to exhibit how the operating conditions affect the lubrication regimes and the fluid film spread in the loaded zone. The adequacy between the choice of lubricant and the bearing tribofinition is sought to optimize the component lifetime.