Restoration and Possible Upgrade of a Historical Motorcycle Part Using Powder Bed Fusion

Reverse engineering is the process of creating a digital version of an existing part without any knowledge in advance about the design intent. Due to 3D printing, the reconstructed part can be rapidly fabricated for prototyping or even for practical usage. To showcase this combination, this study presents a workflow on how to restore a motorcycle braking pedal from material SS316L with the Powder Bed Fusion (PBF) technology. Firstly, the CAD model of the original braking pedal was created. Before the actual PBF printing, the braking pedal printing process was simulated to identify the possible imperfections. The printed braking pedal was then subjected to quality control in terms of the shape distortion from its CAD counterpart and strength assessments, conducted both numerically and physically. As a result, the exterior shape of the braking pedal was restored. Additionally, by means of material assessments and physical tests, it was able to prove that the restored pedal was fully functional. Finally, an approach was proposed to optimize the braking pedal with a lattice structure to utilize the advantages the PBF technology offers.

Dynamic ESPI Evaluation of Deformation and Fracture Mechanism of 7075 Aluminum Alloy

The deformation and fracture mechanism in 7075 aluminum alloy is discussed based on a field theoretical approach. A pair of peak-aged and overaged plate specimens are prepared under the respective precipitation conditions, and their plastic deformation behaviors are visualized with two-dimensional electronic speckle pattern interferometry (ESPI). The in-plane velocity field caused by monotonic tensile loading is monitored continuously via the contour analysis method of ESPI. In the plastic regime, the peak-aged specimen exhibits a macroscopically uniform deformation behavior, while the annealed specimen exhibits non-uniform deformation characterized by a localized shear band. The occurrence of the shear band is explained by the transition of the material’s elastic resistive mechanism from the longitudinal force dominant to shear force dominant mode. The shear force is interpreted as the frictional force that drives mobile dislocations along the shear band. The dynamic behavior of the shear band is explained as representing the motion of a solitary wave. The observed decrease in the solitary wave’s velocity is accounted for by the change in the acoustic impedance with the advancement of plastic deformation.

Structure-function relations of primate lower incisors: a study of the deformation of Macaca mulatta dentition using electronic speckle pattern interferometry (ESPI)

Teeth adopt a variety of different morphologies, each of which is presumably optimized for performing specific functions during feeding. It is generally agreed that the enamel cap is a crucial element in controlling the mechanical behavior of mammalian teeth under load. Incisors are particularly interesting in terms of structure-function relations, as their role in feeding is that of the 'first bite'. However, little is known how incisor cap morphology is related to tooth deformation. In the present paper we examine the mechanical behavior of mandibular central incisors in the cercopithecine primate Macaca mulatta under loads similar to those encountered during ingestion. We map three-dimensional displacements on the labial surface of the crown as it is compressed, using electronic speckle pattern interferometry (ESPI), an optical metrology method. In addition, micro-computed tomography is used to obtain data regarding the morphology of the enamel cap, which in the M. mulatta lower incisors exhibits missing or very little enamel on the lingual face. The results showed that although compressed along a longitudinal axis, deformation in the incisors mostly occurred in the lingual direction and orthogonal to the direction of the applied load. Both isolated, embedded teeth and teeth in the mandible showed considerable lingual deformation. Incisor deformation in the mandible was generally greater, reflecting the additional freedom of movement enabled by the supporting structures. We show that the association with adjacent teeth in the arch is significant for the behavior of the tooth under load. Finally, loading two teeth simultaneously in the mandible showed that they work as one functional unit. We suggest that these results demonstrate the importance of enamel cap morphology in directing deformation behavior; an ability stemming from the stiffness of the enamel cap overlying the more pliable dentin.