Novel Method for Failure Modes Detection in UV-Cured Clear Coated Polymer for Automotive Interior Mechatronic Devices.

Plastic parts used in automotive interior are difficult to coat, due to their low surface energies as well as their sensitivity to temperature and solvents, rendering the development of coating systems for such substrates challenging. Automotive customer requirements are explicit and clear, mainly focused on functional and surface defects. A new failure modes detection methodology of UV clear coated polymers for automotive interior, obtained by a multi-step manufacturing process, is proposed. The polymer complex parts analyzed in this paper are manufactured in various steps as follows: two components plastic injection molding, primer coating, laser engraving, and UV-cured clear coating. The failure modes detection methodology of the parts within each process step is investigated using different tests and analyses as follows: surface tension test, painting adhesion test, optical 3D measuring, energy dispersive X-ray analysis (EDX), and microscopy. A design of the experiments (DoE) based on the Taguchi technique with the aim to detect the influence of the main factors that lead to surface defects was performed. The proposed methodology is validated by a case study. The results showed that the mold temperature and the laser engraving current have a significant influence on the surface defect occurrence. Additionally, a possible contamination of the molding tool can generate the defects. A solution to reduce the occurrence of the failures was proposed, reducing the defect rate from 50% to 0.9%.

Evaluating the Quality Surface Performance of Additive Manufacturing Systems: Methodology and a Material Jetting Case Study.

The performance characterization of the manufacturing processes for additive manufacturing (AM) systems is a significant task for their standardization and implementation in the industry. Also, there is a large diversity of materials used in different AM processes. In the present paper, a methodology is proposed to evaluate, in different directions, the performance of an AM process and material characterization in terms of surface quality. This methodology consists of eight steps, based on a new surface inspection artifact and basic artifact orientations. The proposed artifact with several design configurations fits different AM systems sizes and meets the needs of customers. The effects of main factors on the surface roughness of up-facing platens of the artifacts are investigated using the statistical design of experiments. The proposed methodology is validated by a case study focused on PolyJet material jetting technology. Samples are manufactured of photopolymer resins and post-processed. Three factors (i.e., artifact orientation, platen orientation, and finish type) are considered for the investigation. The case study results show that the platen orientation, finish type, and their interaction have a significant influence on the surface roughness (Ra). The best Ra roughness results were obtained for the glossy finish type in the range of 0.5⁻4 µm.

Reliability Estimation of Parameters of Helical Wind Turbine with Vertical Axis.

Due to the prolonged use of wind turbines they must be characterized by high reliability. This can be achieved through a rigorous design, appropriate simulation and testing, and proper construction. The reliability prediction and analysis of these systems will lead to identifying the critical components, increasing the operating time, minimizing failure rate, and minimizing maintenance costs. To estimate the produced energy by the wind turbine, an evaluation approach based on the Monte Carlo simulation model is developed which enables us to estimate the probability of minimum and maximum parameters. In our simulation process we used triangular distributions. The analysis of simulation results has been focused on the interpretation of the relative frequency histograms and cumulative distribution curve (ogive diagram), which indicates the probability of obtaining the daily or annual energy output depending on wind speed. The experimental researches consist in estimation of the reliability and unreliability functions and hazard rate of the helical vertical axis wind turbine designed and patented to climatic conditions for Romanian regions. Also, the variation of power produced for different wind speeds, the Weibull distribution of wind probability, and the power generated were determined. The analysis of experimental results indicates that this type of wind turbine is efficient at low wind speed.