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    Effect of fiber set-up and density on mechanical behavior of robotic 3D-printed composites
    (Ice Publishing, 2022) İpekçi, Ahmet; Ekici, Bulent
    The further development of composite manufacturing methods is characterized by the progress of their mechanical properties which are widely used in many applications as automotive, aerospace, and marine industries. The automated composite production techniques are as follows: automatic tape layering, automatic fiber placement, and filament winding methods used in many industries. Photopolymerized composites and their additive manufacturing methods are promising with new advances in technology. This method for printing continuous fiber-reinforced plastic composite parts by a six-axis industrial robotic arm is based on fused deposition modeling technology. The objective of this work is to obtain a better understanding of the mechanical properties of robotic three-dimensional printed photopolymer resin continuous fiberglass-reinforced composites (CFGRCs) as a function of different printing speeds (10, 20 and 30mm/s), fiber densities (45, 55 and 65%), and fiber orientations (0, 0/90 and +/- 45 degrees). This work infers that mechanical properties are significantly affected by the fiber density and fiber orientation of CFGRC. With this method, approximately 300MPa tensile strength can be obtained and structurally preferred instead of ferrous materials in many areas.
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    Experimental and statistical analysis of robotic 3D printing process parameters for continuous fiber reinforced composites
    (Sage Publications Ltd, 2021) Ipekci, Ahmet; Ekici, Bulent
    3D printing technology has gradually taken its place in many sectors. However, expected performance cannot be obtained from the structural parts with this method due to the raw material properties and constraints of Cartesian motion systems. This technology cannot replace structural parts produced by traditional manufacturing methods. In order to avoid these constraints, it is preferred to use continuous fiber reinforced polymer composites in many areas such as automotive and aerospace industries due to their low weight and high specific strength properties. These automated composite manufacturing methods currently have limited production of geometric shapes due to the need for additional molds and production as flat surfaces. To overcome all these constraints, fiberglass reinforced ultraviolet ray-curing polymer matrix composite material are selected for robotic 3 D printing process and various parameters are examined. Fiber-polymer combination and layer structure formation was examined. Scanning Electron Microscopy (SEM) images of sections of 3 D printed test samples were taken and fiber resin curing was examined. The nozzle diameter, printing speed, fiber density and Ultra Violet (UV) light intensity parameters, which will provide effective 3 D printing process, are optimized with the Taguchi method. Tensile strength, flexural strength and izod impact values are considered as result parameters for optimization. It was found that it would be appropriate for 3D printing with a 1.0 mm nozzle diameter, 600 tex fiber density, 4 UV light, 600 mm/min printing speed. With these 3D printing process parameters, approximately 125 MPa tensile strength and 450 MPa flexural strength can be obtained. With this study, support and contribution was provided to researchers, composite producers, tool manufacturer and literature who want to use and develop this 3D printing process.
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    Graphene oxide/epoxy acrylate nanocomposite production via SLA and importance of graphene oxide surface modification for mechanical properties
    (Emerald Group Publishing Ltd, 2021) Uysal, Emrah; Cakir, Mustafa; Ekici, Bulent
    Purpose Traditional nanocomposite production methods such as in situ polymerization, melt blending and solvent technique, have some deficits. Some of these are non-homogeneous particle distribution, setup difficulties, time-consuming and costly. On the other hand, three-dimensional printing technology is a quite popular method. Especially, Stereolithography (SLA) printing offers some benefits such as fast printing, easy setup and smooth surface specialties. Furthermore, surface modification of Graphene Oxide (GO) and its effects on polymer nanocomposites are quite important. The purpose of this study is to examine the effect of surface modification of GO nanoparticles on the mechanical properties and morphology of epoxy acrylate (BisGMA/1,6 hexane diol diacrylate) matrix nanocomposites. Design/methodology/approach In this study, Ultraviolet (UV) curable end groups of synthesized resin were linked to functional groups of graphene oxide, which are synthesized by the Tour method, which is a kind of modified Hummer method. In addition, synthesized GO nanoparticle's surfaces were modified by 3-(methacryloyloxy) propyl trimethoxysilane. Significant weight percentages of GO were added into the epoxy acrylate resin. Different Wt.% of modified graphene oxide/acrylate resins was used to print test specimens with SLA type three-dimensional printer. Findings Surface modification has a significant effect on tensile strength for graphene oxide nanoparticles contained composites. In addition, a specific trend was not observed for tensile test results of non-modified graphene oxide. The tendency of impact and hardness test finding were similar for both surfaces modified and non-modified nanoparticles. Finally, the distribution of particles was homogeneous. Originality/value This paper is unique because of the inclusion of both surface modifications of graphene oxide nanoparticles and SLA production of nanocomposites with its own production of three-dimensional printer and photocurable polymer resin.
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    An innovative composite elbow manufacturing method with 6-axis robotic additive manufacturing for fabrication of complex composite structures
    (Sage Publications Ltd, 2024) Ipekci, Ahmet; Ekici, Bulent
    Filament winding method is the most commonly used method to produce profiles with different cross sections as composite product manufacturing. In this method, fiber material is wound with resin at different angles on a mold that has a suitable cross section shape. As a winding strategy, angled and helical winding can be done. Motion planning for this process is done with geodesic and nongeodesic theories. Requirement to use mold in the filament winding method increases the cost. Also, there is an obligation to helical windings. In winding of different layers, 90 degrees angle cannot be given between the layers. To overcome all these constraints, UV curing can be achieved using photopolymer resin and continuous fiber glass fiber with the help of robotic additive manufacturing technology. Toolpath strategies for production has a key role in this work. As a tool path strategy, nonplanar slicing can be done and manufactured composite elbow in angular layers without mold. Then, under favour of 6-axis mobility of the industrial robot arm, layers can be obtained at exactly 90 degrees angle. In addition, in this method, unlike other winding methods, internal voids, i.e. a filling rate, can be given within the cylindrical encircled layers. In order to verify whether the elbows produced with this method meet the requirements of the desired applications in the industry in terms of mechanical properties, at different filling rates (50%, 75%, 100%), winding turns (0 and 1/8), and different fiber densities (45%, 55% and 65%) 90 degrees curved composite elbows were produced and their internal pressure strength tests were tested. Afterwards, an optimization study was carried out with the Taguchi method for the production parameters that will maximize the internal pressure strength. According to the results of the optimization study, it is seen that it is appropriate to choose the printing parameters that will obtain the highest internal pressure strength values for production with this method, 100% fill rate, 65% fiber density and 0 degrees winding angle. The products made of this process have the advantage of easy-shaping, reasonable ratio of axial strength and encircled strength, specification easy-unifying, stable product quality.