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    Öğe
    Experimental study and hybrid optimization of material extrusion process parameters for enhancement of fracture resistance of biodegradable nanocomposites
    (Pergamon-Elsevier Science Ltd, 2023) Seyedzavvar, Mirsadegh; Boga, Cem; Zehir, Burcak
    Among the additive manufacturing processes, the material extrusion (ME) is the most popular and affordable technique in production of a wide range of products, from prototypes to the final products, for different industrial sectors. The most popular raw material in this process is the biodegradable polylactic acid (PLA) polymer that offers ease of production in relatively low price and wide applications in synthesis of medical proteases. However, the mechanical strength of fabricated samples and their resistance against the fracture loadings, which are critical for components synthesized for medical applications, are strongly dependent on the ME process parameters and the composition of the base material. Therefore, this study is aimed to address both the strengthening mechanisms of inorganic CaCO3 nanoadditives in the PLA matrix and the influence of ME process parameters on the fracture resistance of fabricated samples. To this aim, the PLA/CaCO3 nanocomposite filaments have been produced by mix-blending/extrusion tech-nique and were employed to fabricate tensile and fracture test samples in ME process under different sets of parameters, including printing speed, layer thickness, filling ratio and printing pattern, determined by Taguchi L27 orthogonal array. The fracture experiments were conducted on a uniaxial tensile test machine using a specially designed fixture that makes the application of mixed-mode loading on fracture samples possible. The results of fracture toughness of specimens were employed as input data to model the response of fabricated samples and to determine the ME parameter levels and nanoparticle concentrations for maximum fracture resistance of fabri-cated samples based on a hybrid algorithm of artificial neural network and ant colony optimi-zation (ANN/ACO). Differential scanning calorimetry was used to characterize the thermal features (i.e. glass transition, crystallization and melting temperatures) as well as the degree of crystallization of ME samples. Scanning electron microscopy of fracture surfaces were employed to study the influence of ME parameters and CaCO3 nanoadditives on the characteristics of fracture of 3D printed specimens under various modes of loading. Overall, the results showed that the effects of ME parameters on the fracture behavior of 3D printed samples are highly inter-connected and, in the case of a semicrystalline polymer, are highly dependent on the physical characteristics of the fabrication process, including the heat transfer and crystallization rate of the matrix.
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    Öğe
    Exploring mixed-mode fracture behavior and mechanical properties of selective laser sintered polyamide 12 components
    (Emerald Group Publishing Ltd, 2024) Zehir, Burcak; Seyedzavvar, Mirsadegh; Boga, Cem
    PurposeThis study aims to comprehensively investigate the mixed-mode fracture behavior and mechanical properties of selective laser sintering (SLS) polyamide 12 (PA12) components, considering different build orientations and layer thicknesses. The primary objectives include the following. Conducting mixed-mode fracture and mechanical analyses on SLS PA12 parts. Investigating the influence of build orientation and layer thickness on the mechanical properties of SLS-printed components. Examining the fracture mechanisms of SLS-produced Arcan fracture and tensile specimens through experimental methods and finite element analyses.Design/methodology/approachThe research used a combination of experimental techniques and numerical analyses. Tensile and Arcan fracture specimens were fabricated using the SLS process with varying build orientations (X, X-Y, Z) and layer thicknesses (0.1 mm, 0.2 mm). Mechanical properties, including tensile strength, modulus of elasticity and critical stress intensity factor, were quantified through experimental testing. Mixed-mode fracture tests were conducted using a specialized fixture, and finite element analyses using the J-integral method were performed to calculate fracture toughness. Scanning electron microscopy (SEM) was used for detailed morphological analysis of fractured surfaces.FindingsThe investigation revealed that the highest tensile properties were achieved in samples fabricated horizontally in the X orientation with a layer thickness of 0.1 mm. Additionally, parts manufactured with a layer thickness of 0.2 mm exhibited favorable mixed-mode fracture behavior. The results emphasize the significance of build orientation and layer thickness in influencing mechanical properties and fracture behavior. SEM analysis provided valuable insights into the failure mechanisms of SLS-produced PA12 components.Originality/valueThis study contributes to the field of additive manufacturing by providing a comprehensive analysis of the mixed-mode fracture behavior and mechanical properties of SLS-produced PA12 components. The investigation offers novel insights into the influence of build orientation and layer thickness on the performance of such components. The combination of experimental testing, numerical analyses and SEM morphological observations enhances the understanding of fracture behavior in additive manufacturing processes. The findings contribute to optimizing the design and manufacturing of high-quality PA12 components using SLS technology.
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    Öğe
    Molecular dynamics simulation and experimental investigation of mechanical properties of calcium carbonate and graphene reinforced polylactic acid nanocomposites
    (Springer, 2023) Zehir, Burcak; Boga, Cem; Seyedzavvar, Mirsadegh
    ContextThe use of Molecular Dynamics (MD) simulations to examine the mechanical characteristics of polymer composites reinforced with calcium carbonate (CaCO3) and graphene (GR) is represented in this work. The effects of CaCO3 and GR nanoadditives in polylactic acid (PLA) matrix in different concentrations were evaluated using the results of MD simulations. Experimental analyses have been conducted to validate the results of MD based on the mechanical properties of fabricated nanocomposites, including modulus of elasticity, shear modulus, and Poisson's ratio. The modeling, computation, and analysis of several simulations on the improved mechanical characteristics of PLA/CaCO3 and PLA/GR nanocomposites are introduced and discussed. The results revealed that the addition of GR nanoparticles were more effective in enhancing the mechanical properties of PLA components as compared with that of CaCO3 nanoparticles, as the modulus of elasticity, shear modulus and Poisson's ratio increased by approximately 21%, 17%, and 16% for addition of 3 wt% GR nanoparticles in the PLA matrix, respectively.MethodsThe mechanical behavior of PLA/CaCO3 and PLA/GR nanocomposites have been simulated based on the molecular dynamic technique using material studio (MS) that enabled the analyses of synergy between the polymer molecules and the nanoparticles. Molecular models for a system of nanocomposites were built by embedding the nano-clusters into an amorphous PLA matrix. Nanoparticles have been modeled as spherical nanoclusters of graphite and calcite unit cells. Molecular models of the pure PLA matrix were also developed for comparison. The relaxed systems of MD simulations have been carried out to calculate the mechanical properties of nanocomposites containing 1, 3 and 5 wt% nanofiller contents. To validate the results of the simulations, the PLA/CaCO3 and PLA/GR nanocomposite granules, containing different weight ratios of the nanofillers in the matrix, have been synthesized by melt-blending technique. These granules have been used to produce tensile test samples by injection molding technique, with different fractions of nanoparticles in the matrix, to study the effects of such nanoadditives on the mechanical properties of the PLA nanocomposites.