A Study on the Production of Riblet Patterns Providing Micro-scale Flow Control through FDM-type 3D Printers

Year 2024, , 166 - 175, 27.02.2024

Volkan Korkut , Hurrem Akbıyık

https://doi.org/10.35414/akufemubid.1285987

Abstract

This study explores the Fused Deposition Modeling (FDM) additive manufacturing method as a practical alternative for flow characterization applications critical in aerospace technology. While there are significant studies in the literature on high-budget FDM devices for manufacturing high-dimensional consistency parts, research focusing on sub-millimeter riblet geometries using more accessible, practical, and flexible open-source devices remains limited. In this study, a printer that can be mechanically and programmatically modified was used to create parallel riblet patterns resembling wing structures on plates. Microscopic examinations and measurements were conducted on these riblets to address encountered issues. Observations revealed that hardware elements such as nozzle-table distance and nozzle circularity are crucial for homogeneous material extrusion. Additionally, it was observed that software-defined parameters like line width and flow rate significantly affect riblet dimensions. Particularly in experiments involving calibration of these parameters in open-source concept devices, riblet width, inter-riblet spacing, and riblet height were achieved with a high accuracy error rate of up to 1.83%, 1.33%, and 0.19%, respectively. Consequently, this study demonstrated the feasibility of producing riblets in this size and precision using widely available, cost-effective, and customizable FDM devices. Considering the significance of riblet structures in aerospace industries for flow control and surface modifications, this research aims to provide critical insights for the practical and effective production of more complex surface profiles in research and development activities.

Keywords

FDM, 3d printing, Flow control, Riblet, Airfoil surface

FDM-tipi 3 Boyutlu Yazıcılar ile Mikro Ölçekte Akış Kontrolü Sağlayabilen Riblet Desenlerinin Üretimine Yönelik bir Çalışma

Abstract

Bu çalışma, havacılık ve uzay teknolojilerinde kritik öneme sahip olan akış karakterizasyonu uygulamalarına pratik bir alternatif olarak Fused Deposition Modelling (FDM)-tipi eklemeli imalat yöntemini araştırmaktadır. Literatürde, yüksek bütçe gerektiren FDM cihazlarıyla, yüksek boyutsal tutarlılıkta parça imalatı yapılabilmesi üzerine önemli çalışmalar mevcut olmasıyla birlikte; daha erişilebilir, pratik ve esnek bir kullanım imkanı sunan açık-kaynaklı cihazlar ile milimetre-altı riblet geometrileri üretiminin detayları üzerine yürütülmüş araştırmaların sayısı kısıtlıdır. Bu bağlamda çalışmada, mekanik ve yazılımsal olarak modifiye edilebilen bir yazıcı kullanılmış olup, kanat yapısını temsil eden plakalar üzerine, birbirine paralel riblet desenleri üretilmiştir. Ribletler üzerinde mikroskopik inceleme ve ölçümler gerçekleştirilerek, karşılaşılan sorunların çözümüne yönelik araştırmalar yapılmıştır. Gözlemler doğrultusunda, ilk etapta, nozzle-table mesafesi ve nozzle daireselliği gibi donanımsal unsurların homojen bir malzeme ekstrüzyonu açısından önem taşıdığı açığa çıkarılmıştır. Mekanik faktörlerin yanı-sıra, yazılımsal olarak belirlenen çizgi genişliği ve akış oranı parametrelerinin, riblet boyutları üzerinde belirleyici birer etken olduğu gözlemlenmiştir. Özellikle açık-kaynak konseptine dayalı cihazlarda bu parametrelerin kalibrasyonuna yönelik çözümler içeren deneylerin sonucunda; sırasıyla riblet genişliği, ribletler-arası boşluk mesafesi ve riblet yüksekliği olacak şekilde, hata miktarı en fazla %1,83, %1,33 ve %0,19 gibi yüksek doğrulukta riblet profilleri elde edilebilmiştir. Sonuçta, yaygın kullanılan, düşük maliyetli ve modifiye edilebilir yapıdaki FDM cihazlarıyla, bu boyutlarda ve doğrulukta riblet üretimi yapılabilmesine dair bulgular sunulmuştur. Akış kontrolü ve yüzey modifikasyonları alanlarında kullanılan riblet yapılarının havacılık ve uzay endüstrisindeki önemi göz önünde bulundurulduğunda bu çalışma, araştırma-geliştirme faaliyetlerinde kullanılabilecek daha karmaşık yüzey profillerinin, kısa sürelerde, pratik ve efektif bir şekilde üretilebilmesi için kritik bilgileri literatüre kazandırmayı amaçlamaktadır.

Keywords

FDM, 3 boyutlu yazıcı, akış kontrol, riblet, kanat yüzeyi

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