Experimental substantiation of the technology for manufacturing composite parts based on a viscous metal-polymer

ABSTRACT

The article deals with an experimental study of the technological process of obtaining a composite ABS, a metal-polymer part. As the title implies the article describes a method and device for the manufacture of composite parts based on the method of vacuum suction of a viscous metal-polymer into a shell form. Recommendations are given on the technological modes of filling the mould, taking into account the presence of vibration in the process of filling the mould with a metal-polymer, as well as the Reynolds number parameter for establishing a laminar flow of the metal-polymer in the technological mould cavities. The study of the strength of the designed composite part has been carried out using the finite element method of the APM FEM module. The calculations of the strength and stiffness of parts made of ABS, metal-polymer and metal make it possible to compare the strength characteristics of parts made by various methods. Relevant recommendations are given on the use of a composite part reinforced with a metal-polymer in the field of mechanical engineering.

KEYWORDS:

• Composite
• metal-polymer
• modelling
• vacuum
• vibrations
• additive manufacturing
• topological optimisation
• Reynolds number

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

The data presented in this study is available upon request from the respective author. The data are not publicly available as they are also part of ongoing research.

Supplementary material

Supplemental data for this article can be accessed online at https://doi.org/10.1080/14484846.2024.2343449

Additional information

Funding

The study was supported by the Russian Science Foundation grant No. 23-79-10022, https://rscf.ru/project/23-79-10022/.

Notes on contributors

Andrey Polshin

Polshin Andrey Alexandrovich - completed this work during his graduate studies at BSTU. V.G. Shukhova, Russia. This concept was his own original idea and reflects his interest in studying the processes of producing composite structures. He plans to develop the proposed experience to create metal-metal-polymer compositions. His approaches aim to reduce the cost of additive manufacturing in metal printing. His innovative ideas will significantly reduce the cost and production time of various machine parts. His passion is the application of generative design in structural design and it is for these complex structures that his research is implemented.

Nickolai Lubimyi

Lyubimy Nikolai Sergeevich - Associate Professor at BSTU named after. V.G. Shukhov, majoring in mechanical engineering technology. His scientific and engineering research is focused on the development of new technologies for the production of engineering products. He developed the design of a vibration-vacuum unit and implemented the experimental setup presented in the work.

Boris Chetverikov

Chetverikov Boris Sergeevich - associate professor of BSTU named after. V.G. Shukhov, majoring in automation of machine-building production. He devoted his career to developing equipment for the production of plastic products. In his work he provided expert support in the development of equipment for casting metal polymers. Thanks to his work, it was possible to select technological casting modes that ensured the laminar flow of the metal polymer in channels of complex shape.

Mihail Chepchurov

Chepchurov Mikhail Sergeevich - Professor of the Department of Mechanical Engineering Technology BSTU named after V.G. Shukhov. He has a Doctor of Technical Sciences degree in two specialties: automation and mechanical engineering. He developed the concept of using metal polymers to form durable surfaces of complex shapes. This concept was later transformed into the results of this work.

Ardalion Maltsev

Maltsev Ardalion Konstantinovich - completed this work while studying for a master’s degree at BSTU. V.G. Shukhova, Russia. He is passionate about researching the unique properties of metal-polymer materials. He devoted his activities to the development of technologies for producing composite structures using metal polymers.

Alexander Tikhonov

Tikhonov Alexander Andreevich - completed this work during his graduate studies at BSTU. V.G. Shukhova, Russia. He made a significant contribution to the implementation of experimental work. In his research activities, he pays special attention to additive technologies in modern manufacturing. He is passionate about identifying economically feasible opportunities to expand additive manufacturing in global manufacturing.