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WSdesign: a mathematical design method for generating uniform and functionally gradient/hybrid wave springs, fabricated using additive manufacturing processes

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Abstract

Design for additive manufacturing (DfAM) enables the design and fabrication of intricate but application-based functionally optimized geometries by reducing the manufacturing time. It also gave unlimited design freedom to alter any specific parameter and regenerate the design with improved mechanical properties. However, designing a complex and application-specific component needs comprehensive knowledge of drawing, intended usage, high expertise, and command of designing software with ample time. Mechanical springs, e.g., wave springs of uniform/complex shaped designs, consume a significant amount of manual hard work. A new design tool, WSdesign, is developed for constructing wave springs of different morphologies with uniform or varying design parameters or a combination of both. A graphical user interface (GUI) was developed in which the user can select the type of wave spring, which can be either uniform, functional gradient, or hybrid with parametric variation defined through Python code. The code is directly run in Autodesk Fusion 360 software which is used to transform that code into a 3D model with all defined features and can be saved in different formats or can be directly printed. Two designs, i.e., rectangular and variable thickness wave springs, were designed each using WSdesign and SolidWorks (manual method), manufactured, and analyzed by performing uniaxial compression testing. The results were compared with each other which were further validated by finite element analysis and found that both design strategies have negligible variations. Furthermore, several designs of complex-shaped wave springs were successfully designed and manufactured using fused deposition modeling (FDM), stereolithography (SLA), and powder bed fusion (MJF) technology with different materials, resulting in a good surface finish, smooth printability, and less dimensional variation, which proves the versatility of WSdesign. In addition, this methodology also enables to design of application-based wave springs for research and industrial usage as per load requirements without having in-depth design expertise and spending much less time.

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Funding

This work was financially supported by the High-Speed 3D Printing Research Center (grant no. 108P012) from the Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) Taiwan.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Road, Taipei, 106, Taiwan, Republic of China

    Muhammad Rizwan ul Haq, Hamza Azam & Jeng-Ywan Jeng

  2. High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, No. 43, Section 4, Keelung Road, Taipei, 106, Taiwan, Republic of China

    Muhammad Rizwan ul Haq, Hamza Azam & Jeng-Ywan Jeng

  3. Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong SAR 999077, China

    Aamer Nazir

  4. Academy of Innovative Semiconductor and Sustainable Manufacturing, National Cheng Kung University, No.1, University Road, Tainan City 701, Tainan, Taiwan, Republic of China

    Jeng-Ywan Jeng

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  1. Muhammad Rizwan ul Haq
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Correspondence to Jeng-Ywan Jeng.

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Haq, M.R.u., Nazir, A., Azam, H. et al. WSdesign: a mathematical design method for generating uniform and functionally gradient/hybrid wave springs, fabricated using additive manufacturing processes. Int J Adv Manuf Technol 121, 7763–7778 (2022). https://doi.org/10.1007/s00170-022-09818-5

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