Additive manufacturing of fused deposition modeling for carbon fiber-PLA (CF-PLA) composites: The effects of tensile and flexural properties of process parameters

2021 ◽  
Author(s):  
Abhay Mishra ◽  
Vivek Srivastava ◽  
Nitin Gupta
Keyword(s):  
Carbon Fiber ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Processing Parameters ◽  
Variance Analysis ◽  
Flexural Properties ◽  
3D Cad ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Factor Design

Abstract In this paper the effect of process parameters on the tensile and flexural properties has been analyzed. We have used commercially available FDM 3D printer and material (Carbon fiber -PLA). When various processing parameters, especially when no linear processing parameters are defined, the complete factor design of experiments (DOE) is hard to research. Furthermore, a large number of samples are needed to completely exploit the exact processing parameters. The key effects of four processing parameters for the FDM process, i.e. layer height, infill density, printing speed and infill pattern, are examined in this document in the DOE of Taguchi. The mechanical characteristics of the fabricated FDM components express the power of the processing parameters. We have used the Taguchi L9 range of 9 runs with three specimens each to present the work, so 54 different processes were used to make a total of 54 specimens. In comparison to the 3D CAD model, the measurements of the manufactured specimens were tested according to standard ASTM D638 and ASTM D790. Variance analysis (ANOVA) is generated using Design Expert tools in order to assess the importance of variables and their tensile and flexural strength interactions. After doing Variance analysis (ANOVA) we got the exact parameters in which the mechanical properties are higher.

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.

Additive Manufacturing of CFRP Composites Using Fused Deposition Modeling: Effects of Process Parameters

2016 ◽  
Author(s):  
Fuda Ning ◽  
Weilong Cong ◽  
Zhenyuan Jia ◽  
Fuji Wang ◽  
Meng Zhang
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Tensile Properties ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Cfrp Composites ◽  
Cfrp Composite ◽  
Deposition Modeling ◽  
Nozzle Temperature

Fused deposition modeling (FDM) is one of the attractive additive manufacturing (AM) technologies for rapid prototyping with complex structures in a short timeframe. Thermoplastics are currently used as common feedstocks to fabricate prototypes in FDM process. However, FDM-fabricated pure thermoplastic parts cannot be used as load-bearing parts in the actual applications due to their limited tensile strength. Such condition could be improved by developing carbon fiber reinforced plastic (CFRP) composites using FDM for potential industrial end users. It is crucial that proper selections of FDM process parameters during fabricating CFRP composite parts could ensure the part quality and properties. However, the effects of FDM process parameters on the tensile properties of CFRP composites have not been explored. In this paper, CFRP composite specimens with 5 wt% carbon fiber content were fabricated using a FDM machine. Tensile testing was conducted to obtain the tensile properties. The effects of process parameters (including infill speed, nozzle temperature, and layer thickness) on the tensile properties of FDM-fabricated CFRP composite parts were investigated.

Assessing the effect of FDM processing parameters on mechanical properties of PLA parts using Taguchi method

2021 ◽  
pp. 089270572110530
Author(s):  
Nagarjuna Maguluri ◽  
Gamini Suresh ◽  
K Venkata Rao
Keyword(s):  
Mechanical Properties ◽  
Tensile Properties ◽  
Fused Deposition Modeling ◽  
Fracture Strain ◽  
Processing Parameters ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Nozzle Temperature ◽  
Experimental Runs ◽  
Printing Speed

Fused deposition modeling (FDM) is a fast-expanding additive manufacturing technique for fabricating various polymer components in engineering and medical applications. The mechanical properties of components printed with the FDM method are influenced by several process parameters. In the current work, the influence of nozzle temperature, infill density, and printing speed on the tensile properties of specimens printed using polylactic acid (PLA) filament was investigated. With an objective to achieve better tensile properties including elastic modulus, tensile strength, and fracture strain; Taguchi L8 array has been used for framing experimental runs, and eight experiments were conducted. The results demonstrate that the nozzle temperature significantly influences the tensile properties of the FDM printed PLA products followed by infill density. The optimum processing parameters were determined for the FDM printed PLA material at a nozzle temperature of 220°C, infill density of 100%, and printing speed of 20 mm/s.

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