Pengembangan gear dengan proses additive manufacturing berbasis lattice structure dengan dimensi variasional

Vynna Alviolina Indriyana; Gandjar Kiswanto; Ridho Irwansyah

doi:10.71452/rpb15d50

Authors

Vynna Alviolina Indriyana University of Indonesia Author
Gandjar Kiswanto Author
Ridho Irwansyah Author

DOI:

https://doi.org/10.71452/rpb15d50

Keywords:

Gear, multi material, Additive Manufacturing, Lattice

Abstract

Gears are fundamental components in mechanical systems, where reducing weight without compromising strength is a key engineering challenge. This study introduces a multi-material gear with a lattice structure fabricated by Additive Manufacturing (AM). The design integrates an outer gear of Ti-6Al-4V for high strength and wear resistance with an inner gear of 316L stainless steel for structural support. Weight reduction was achieved by generating a diamond wire cube lattice with variable strut diameters, optimized using stress distribution data from finite element analysis and clustering with the K-means algorithm. Structural analysis through ANSYS Explicit Dynamics and fatigue simulations confirmed that stresses remained below the ultimate tensile strength of both materials, ensuring reliable service life. Thermal analysis with CFD indicated a maximum operating temperature of 64.1 °C, within the typical gear range of 50–140 °C. The proposed design reduces gear mass by 34.8% compared to a solid model, demonstrating the feasibility of multi-material AM with lattice optimization for lightweight and durable gear applications.

References

V. J. Kharat et al., “Additive manufacturing (3D printing): A review of materials, methods, applications and challenges,” Mater Today Proc, Nov. 2023, doi: 10.1016/j.matpr.2023.11.033.

D. M. Hajare and T. S. Gajbhiye, “Additive manufacturing (3D printing): Recent progress on advancement of materials and challenges,” Mater Today Proc, vol. 58, pp. 736–743, Jan. 2022, doi: 10.1016/j.matpr.2022.02.391.

K. V. Wong and A. Hernandez, “A Review of Additive Manufacturing,” ISRN Mechanical Engineering, vol. 2012, pp. 1–10, Aug. 2012, doi: 10.5402/2012/208760.

K. R. Ryan, M. P. Down, N. J. Hurst, E. M. Keefe, and C. E. Banks, “Additive manufacturing (3D printing) of electrically conductive polymers and polymer nanocomposites and their applications,” Jul. 01, 2022, Elsevier B.V. doi: 10.1016/j.esci.2022.07.003.

J. Tkac, S. Samborski, K. Monkova, and H. Debski, “Analysis of mechanical properties of a lattice structure produced with the additive technology,” Compos Struct, vol. 242, Jun. 2020, doi: 10.1016/j.compstruct.2020.112138.

S. Das, D. L. Bourell, and S. S. Babu, “Metallic materials for 3D printing,” Oct. 01, 2016, Materials Research Society. doi: 10.1557/mrs.2016.217.

Y. Wang et al., “Applications of additive manufacturing (AM) in sustainable energy generation and battle against COVID-19 pandemic: The knowledge evolution of 3D printing,” Jul. 01, 2021, Elsevier B.V. doi: 10.1016/j.jmsy.2021.07.023.

C. Pan, Y. Han, and J. Lu, “Design and optimization of lattice structures: A review,” Sep. 02, 2020, MDPI AG. doi: 10.3390/APP10186374.

J. Elambasseril and M. Brandt, “Artificial intelligence: way forward to empower metal additive manufacturing product development – an overview,” Mater Today Proc, vol. 58, pp. 461–465, Jan. 2022, doi: 10.1016/j.matpr.2022.02.485.

C. Beyer and D. Figueroa, “Design and Analysis of Lattice Structures for Additive Manufacturing,” Journal of Manufacturing Science and Engineering, Transactions of the ASME, vol. 138, no. 12, Dec. 2016, doi: 10.1115/1.4033957.

P. F. Egan, “Design for Additive Manufacturing: Recent Innovations and Future Directions,” Aug. 01, 2023, Multidisciplinary Digital Publishing Institute (MDPI). doi: 10.3390/designs7040083.

W. Tao and M. C. Leu, “Design of lattice structure for additive manufacturing,” in International Symposium on Flexible Automation, ISFA 2016, Institute of Electrical and Electronics Engineers Inc., Dec. 2016, pp. 325–332. doi: 10.1109/ISFA.2016.7790182.

X. Wang, R. Qin, B. Chen, X. Niu, and J. Zhou, “Multi-scale collaborative optimization of lattice structures using laser additive manufacturing,” Int J Mech Sci, vol. 222, May 2022, doi: 10.1016/j.ijmecsci.2022.107257.

A. Kholil, G. Kiswanto, A. Al Farisi, and J. Istiyanto, “Finite Element Analysis of Lattice Structure Model with Control Volume Manufactured Using Additive Manufacturing,” International Journal of Technology, vol. 14, no. 7, pp. 1428–1437, 2023, doi: 10.14716/ijtech.v14i7.6660.

J. Yang et al., “Rational design and additive manufacturing of grain boundary-inspired, multi-architecture lattice structures,” Mater Des, vol. 235, Nov. 2023, doi: 10.1016/j.matdes.2023.112448.

R. Ramadani et al., “Topology optimization and additive manufacturing in producing lightweight and low vibration gear body”, doi: 10.1007/s00170-021-06841-w/Published.

R. Ramadani et al., “Topology optimization and additive manufacturing in producing lightweight and low vibration gear body,” The International Journal of Advanced Manufacturing Technology, vol. 113, no. 11–12, pp. 3389–3399, Apr. 2021, doi: 10.1007/s00170-021-06841-w.

T. Tobie, F. Hippenstiel, and H. Mohrbacher, “Optimizing gear performance by alloy modification of carburizing steels,” Metals (Basel), vol. 7, no. 10, Oct. 2017, doi: 10.3390/met7100415.

M. Zmindak, M. Kaco, and A. Sapietova, “Analysis of the Contact Stresses of Spur Gears Manufactured by 3D Printing from Composite Materials,” MATEC Web of Conferences, vol. 357, p. 06003, 2022, doi: 10.1051/matecconf/202235706003.

Y. Xiong, Y. Tang, Q. Zhou, Y. Ma, and D. W. Rosen, “Intelligent additive manufacturing and design state of the art and future perspectives,” Addit Manuf, vol. 59, Nov. 2022, doi: 10.1016/j.addma.2022.103139.

M. Losertová, M. Štamborská, J. Lapin, and V. Mareš, “Comparison of deformation behavior of 316L stainless steel and Ti6Al4V alloy applied in traumatology COMPARISON OF DEFORMATION BEHAVIOR OF 316L STAINLESS STEEL AND Ti6Al4V ALLOY APPLIED IN TRAUMATOLOGY Original Scientific Paper-Izvorni znanstveni rad,” 2016. [Online]. Available: https://www.researchgate.net/publication/303369275

M. S. F. De Lima and S. Sankaré, “Microstructure and mechanical behavior of laser additive manufactured AISI 316 stainless steel stringers,” Mater Des, vol. 55, pp. 526–532, 2014, doi: 10.1016/j.matdes.2013.10.016.

I. Tolosa, F. Garciandía, F. Zubiri, F. Zapirain, and A. Esnaola, “Study of mechanical properties of AISI 316 stainless steel processed by ‘selective laser melting’, following different manufacturing strategies,” International Journal of Advanced Manufacturing Technology, vol. 51, no. 5–8, pp. 639–647, Nov. 2010, doi: 10.1007/s00170-010-2631-5.

H. D. Nguyen et al., “A critical review on additive manufacturing of Ti-6Al-4V alloy: Microstructure and mechanical properties,” May 01, 2022, Elsevier Editora Ltda. doi: 10.1016/j.jmrt.2022.04.055.

X. Shi et al., “Selective laser melting-wire arc additive manufacturing hybrid fabrication of Ti-6Al-4V alloy: Microstructure and mechanical properties,” Materials Science and Engineering: A, vol. 684, pp. 196–204, Jan. 2017, doi: 10.1016/j.msea.2016.12.065.

A. M. Beese and B. E. Carroll, “Review of Mechanical Properties of Ti-6Al-4V Made by Laser-Based Additive Manufacturing Using Powder Feedstock,” JOM, vol. 68, no. 3, pp. 724–734, Mar. 2016, doi: 10.1007/s11837-015-1759-z.

M. M. . Khonsari and E. Richard. Booser, Applied tribology : bearing design and lubrication. John Wiley & Sons Inc., 2017.

A. E. Ezugwu et al., “A comprehensive survey of clustering algorithms: State-of-the-art machine learning applications, taxonomy, challenges, and future research prospects,” Apr. 01, 2022, Elsevier Ltd. doi: 10.1016/j.engappai.2022.104743.

W. Kwedlo, “A clustering method combining differential evolution with the K-means algorithm,” Pattern Recognit Lett, vol. 32, no. 12, pp. 1613–1621, Sep. 2011, doi: 10.1016/j.patrec.2011.05.010.

M. Kaushik, B. Mathur, and M. B. Mathur, “Comparative Study of K-Means and Hierarchical Clustering Techniques,” 2014. [Online]. Available: https://www.researchgate.net/publication/293061584

Z. J. Cai, X. Q. Zheng, H. Q. Lan, L. N. Wang, S. W. Yang, and R. Shen, “Predictive Model for Scuffing Temperature Field Rise of Spiral Bevel Gears under Different Machining Conditions,” Lubricants, vol. 12, no. 10, Oct. 2024, doi: 10.3390/lubricants12100354.