An experimental study on carbon fiber thickness and layer thickness of depositing material in fused deposition modeling

2020 ◽  
Author(s):  
Purushottam Sharma ◽  
Ajay Kumar Dhanopia ◽  
Dheeraj Joshi
Keyword(s):  
Experimental Study ◽  
Carbon Fiber ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Fiber Thickness

scholarly journals Preparation and Evaluation of the Tensile Characteristics of Carbon Fiber Rod Reinforced 3D Printed Thermoplastic Composites

2020 ◽  
Vol 5 (1) ◽  
pp. 8
Author(s):  
Arivazhagan Selvam ◽  
Suresh Mayilswamy ◽  
Ruban Whenish ◽  
Rajkumar Velu ◽  
Bharath Subramanian
Keyword(s):  
Tensile Strength ◽  
Carbon Fiber ◽  
Layer Thickness ◽  
Shell Thickness ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Thermoplastic Composites ◽  
Critical Parameters ◽  
Fused Deposition ◽  
Deposition Modeling

The most common method to fabricate both simple and complex structures in the additive manufacturing process is fused deposition modeling (FDM). Many researchers have studied the strengthening of FDM components by adding short carbon fibers (CF) or by reinforcing solid carbon fiber rods. In the current research, we sought to enhance the mechanical properties of FDM components by adding bioinspired solid CF rods during the fabrication process. An effective bonding interface of bioinspired CF rods and polylactic acid (PLA) was achieved by triangular interlocking sutures and by employing synthetic glue as the binding agent. In particular, the tensile strength of solid CF rod reinforced PLA samples was studied. Critical parameters such as layer thickness, extruder temperature, extruder speed, and shell thickness were considered for optimization. Significant process parameters were identified through leverage plots using the response surface methodology (RSM). The optimum parameters were found to be layer thickness of 0.04 mm, extruder temperature of 215 °C, extruder speed of 60 mm/s, and shell thickness of 1.2 mm. The results revealed that the bioinspired solid CF rod reinforced PLA (CFRPLA) composite exhibited a tensile strength of 82.06 MPa, which was approximately three times higher than the pure PLA (28 MPa, 66% lower than CFRPLA), acrylonitrile butadiene styrene (ABS) (28 MPa, 66% lower than CFRPLA), polyethylene terephthalate glycol (PETG) (34 MPa, 60% lower than CFRPLA), and nylon (34 MPa, 60% lower than CFRPLA) samples.

Linear model analysis of fused deposition modeling process parameters for obtaining the maximum tensile strength in acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) materials

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Debashis Mishra ◽  
Anil Kumar Das
Keyword(s):  
Tensile Strength ◽  
Carbon Fiber ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Thermoplastic Material ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Speed

PurposeThe purpose of the experimental investigation was to optimize the process parameters of the fused deposition modeling (FDM) technique. The optimization of the process was performed to identify the relationship between the chosen factors and the tensile strength of acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) thermoplastic material, FDM printed specimens. The relationship was demonstrated by using the linear experimental model analysis, and a prediction expression was established. The developed prediction expression can be used for the prediction of tensile strength of selected thermoplastic materials at a 95% confidence level.Design/methodology/approachThe Taguchi L9 experimental methodology was used to plan the total number of experiments to be performed. The process parameters were chosen as three at three working levels. The working range of chosen factors was the printing speed (60, 80 and 100mm/min), 40%, 60% and 80% as the infill density and 0.1mm, 0.2mm and 0.3mm as the layer thickness. The fused deposition modeling process parameters were optimized to get the maximum tensile strength in FDM printed ABS and carbon fiber PLA thermoplastic material specimens.FindingsThe optimum condition was achieved by the process optimization, and the desired results were obtained. The maximum desirability was achieved as 0.98 (98%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.3mm. The strength of the ABS specimen was predicted to be 23.83MPa. The observed strength value was 23.66MPa. The maximum desirability was obtained as 1 (100%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.2mm. The strength of the carbon fiber PLA specimen was predicted to be 26.23MPa, and the obtained value was 26.49MPa.Research limitations/implicationsThe research shows the useful process parameters and their suitable working conditions to print the tensile specimens of the ABS and carbon fiber PLA thermoplastics by using the fused deposition modeling technique. The process was optimized to identify the most influential factor, and the desired optimum condition was achieved at which the maximum tensile strength was reported. The produced prediction expression can be used to predict the tensile strength of ABS and carbon fiber PLA filaments.Practical implicationsThe results obtained from the experimental investigation are useful to get an insight into the FDM process and working limits to print the parts by using the ABS and carbon fiber PLA material for various industrial and structural applications.Social implicationsThe results will be useful in choosing the suitable thermoplastic filament for the various prototyping and structural applications. The products that require freedom in design and are difficult to produce by most of the conventional techniques can be produced at low cost and in less time by the fused deposition modeling technique.Originality/valueThe process optimization shows the practical exposures to state an optimum working condition to print the ABS and carbon fiber PLA tensile specimens by using the FDM technique. The carbon fiber PLA shows better strength than ABS thermoplastic material.

scholarly journals Process Parameter Optimization in Fused Deposition Modeling (FDM) Using Response Surface Methodology (RSM)

2020 ◽  
Author(s):  
Muhammad Salman Mustafa ◽  
Muhammad Qasim Zafar ◽  
Muhammad Arslan Muneer ◽  
Muhammad Arif ◽  
Farrukh Arsalan Siddiqui ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Response Surface Methodology ◽  
Impact Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Experimental Results ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Parameters

Abstract Fused Deposition Modeling (FDM) is a widely adopted additive manufacturing process to produce complex 3D structures and it is typically used in the fabrication of biodegradable materials e.g. PLA/PHA for biomedical applications. However, FDM as a fabrication process for such material needs to be optimized to enhance mechanical properties. In this study, dogbone and notched samples are printed with the FDM process to determine optimum values of printing parameters for superior mechanical properties. The effect of layer thickness, infill density, and print bed temperature on mechanical properties is investigated by applying response surface methodology (RSM). Optimum printing parameters are identified for tensile and impact strength and an empirical relation has been formulated with response surface methodology (RSM). Furthermore, the analysis of variance (ANOVA) was performed on the experimental results to determine the influence of the process parameters and their interactions. ANOVA results demonstrate that 44.7% infill density, 0.44 mm layer thickness, and 20C° printing temperatures are the optimum values of printing parameters owing to improved tensile and impact strength respectively. The experimental results were found in strong agreement with the predicted theoretical results.

Effect of process parameters on flexural strength and surface roughness in fused deposition modeling of PC-ABS material

2021 ◽  
pp. 251659842110311
Author(s):  
Shrikrishna Pawar ◽  
Dhananjay Dolas1
Keyword(s):  
Surface Roughness ◽  
Flexural Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Process Parameters ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Build Orientation ◽  
Fused Deposition ◽  
Deposition Modeling

Fused deposition modeling (FDM) is one of the most commonly used additive manufacturing (AM) technologies, which has found application in industries to meet the challenges of design modifications without significant cost increase and time delays. Process parameters largely affect the quality characteristics of AM parts, such as mechanical strength and surface finish. This article aims to optimize the parameters for enhancing flexural strength and surface finish of FDM parts. A total of 18 test specimens of polycarbonate (PC)-ABS (acrylonitrile–butadiene–styrene) material are printed to analyze the effect of process parameters, viz. layer thickness, build orientation, and infill density on flexural strength and surface finish. Empirical models relating process parameters with responses have been developed by using response surface regression and further analyzed by analysis of variance. Main effect plots and interaction plots are drawn to study the individual and combined effect of process parameters on output variables. Response surface methodology was employed to predict the results of flexural strength 48.2910 MPa and surface roughness 3.5826 µm with an optimal setting of parameters of 0.14-mm layer thickness and 100% infill density along with horizontal build orientation. Experimental results confirm infill density and build orientation as highly significant parameters for impacting flexural strength and surface roughness, respectively.

Effect of layer thickness on irreversible thermal expansion and interlayer strength in fused deposition modeling

2017 ◽  
Vol 23 (5) ◽  
pp. 943-953 ◽  
Author(s):  
Anthony A. D’Amico ◽  
Analise Debaie ◽  
Amy M. Peterson
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Thermal Strain ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact

Purpose The aim of this paper is to examine the impact of layer thickness on irreversible thermal expansion, residual stress and mechanical properties of additively manufactured parts. Design/methodology/approach Samples were printed at several layer thicknesses, and their irreversible thermal expansion, tensile strength and flexural strength were determined. Findings Irreversible thermal strain increases with decreasing layer thickness, up to 22 per cent strain. Tensile and flexural strengths exhibited a peak at a layer thickness of 200 μm although the maximum was not statistically significant at a 95 per cent confidence interval. Tensile strength was 54 to 97 per cent of reported values for injection molded acrylonitrile butadiene styrene (ABS) and 29 to 73 per cent of those reported for bulk ABS. Flexural strength was 18 to 41 per cent of reported flexural strength for bulk ABS. Practical implications The large irreversible thermal strain exhibited that corresponding residual stresses could lead to failure of additively manufactured parts over time. Additionally, the observed irreversible thermal strains could enable thermally responsive shape in additively manufactured parts. Variation in mechanical properties with layer thickness will also affect manufactured parts. Originality/value Tailorable irreversible thermal strain of this magnitude has not been previously reported for additively manufactured parts. This strain occurs in parts made with both high-end and consumer grade fused deposition modeling machines. Additionally, the impact of layer thickness on tensile and flexural properties of additively manufactured parts has received limited attention in the literature.

scholarly journals An Experimental Study on the Energy Consumption and Emission Profile of Fused Deposition Modeling Process

2018 ◽  
Vol 26 ◽  
pp. 920-928 ◽  
Author(s):  
Timothy R. Simon ◽  
Wo Jae Lee ◽  
Benjamin E. Spurgeon ◽  
Brandon E. Boor ◽  
Fu Zhao
Keyword(s):  
Experimental Study ◽  
Energy Consumption ◽  
Fused Deposition Modeling ◽  
Emission Profile ◽  
Fused Deposition ◽  
Modeling Process ◽  
Deposition Modeling

scholarly journals Preparation of Hydrophobic Surface on PLA and ABS by Fused Deposition Modeling

Polymers ◽  
2020 ◽  
Vol 12 (7) ◽  
pp. 1539 ◽  
Author(s):  
Huadong Yang ◽  
Fengchao Ji ◽  
Zhen Li ◽  
Shuai Tao
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Hydrophobic Coatings ◽  
Fused Deposition ◽  
Filling Method ◽  
Deposition Modeling ◽  
Experiment Analysis ◽  
Printing Speed

In the fields of agriculture, medical treatment, food, and packaging, polymers are required to have the characteristics of self-cleaning, anti-icing, and anti-corrosion. The traditional preparation method of hydrophobic coatings is costly and the process is complex, which has special requirements on the surface of the part. In this study, fused deposition modeling (FDM) 3D printing technology with design and processing flexibility was applied to the preparation of hydrophobic coatings on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts, and the relationship between the printing process parameters and the surface roughness and wettability of the printed test parts was discussed. The experimental results show that the layer thickness and filling method have a significant effect on the surface roughness of the 3D-printed parts, while the printing speed has no effect on the surface roughness. The orthogonal experiment analysis method was used to perform the wettability experiment analysis, and the optimal preparation process parameters were found to be a layer thickness of 0.25 mm, the Grid filling method, and a printing speed of 150 mm/s.

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