Investigations for melt flow index of Nylon6-Fe composite based hybrid FDM filament

2016 ◽  
Vol 22 (2) ◽  
pp. 338-343 ◽  
Author(s):  
Harish Garg ◽  
Rupinder Singh
Keyword(s):  
Composite Material ◽  
Melt Flow Index ◽  
Industrial Applications ◽  
Extrusion Temperature ◽  
Filler Material ◽  
Flow Index ◽  
Melt Flow ◽  
Content Type ◽  
Fused Deposition ◽  
Feedstock Material

Purpose This paper aims to carry out experimental investigations highlighting the role of melt flow index (MFI) in fused deposition modelling (FDM) process by varying the proportion of the Fe powder which is being used as a filler material. An attempt has been made to standardize MFI of Nylon6-Fe composite material to be used as hybrid FDM filament. Design/methodology/approach In this research work, it is proposed to make a suitable blend of composite material for FDM filament which can be used directly for rapid tooling applications. Three controllable parameters (namely, composition/proportion of the filler for hybrid filament, extrusion temperature and extrusion load) were studied by using Taguchi L9 orthogonal array (O.A.) MFI which is an indication of flowability has been selected as output parameter. Findings MFI of hybrid composite filament material has been studied, and Taguchi’s L9 O.A. was applied under both the conditions of lower the better type and larger the better type. It is observed that the contribution of the extrusion load, extrusion temperature and proportion of the filler material is almost similar, whether lower the better type situation is considered or larger the better type is considered. Further, an attempt has been made to standardize the MFI of Nylon6-Fe composite material for industrial applications, as no standard is available for composites (presently, ASTM-D-1238-95 standard is being used for plastic based materials only). Originality/value In recent past, researchers have studied and analysed the flow of the material through the nozzle of the FDM machine, but very little work has been reported on study of the flow characteristics of filament material before the composite material is fed into the machine. This research can open new avenues in the field of MFI and deals with comparison of MFI of the existing FDM feedstock material with the new composite material. The developed feedstock material is ferromagnetic in nature and can find wide variety of industrial applications.

On recyclability of thermoplastic ABS polymer as fused filament for FDM technique of additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Kapil Chawla ◽  
Rupinder Singh ◽  
Jaspreet Singh
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Melt Flow Index ◽  
Extrusion Temperature ◽  
Flow Index ◽  
Content Type ◽  
Fused Deposition ◽  
Screw Extrusion ◽  
Twin Screw ◽  
Deposition Modeling

Purpose The thermoplastic polymers do not decompose easily due to the presence of long-chain stable polymeric structure, and thus, causes serious effects on the environment. Recycling of these polymer wastes becomes the only solution to minimize their adverse effects on the environment. The purpose of this study was to explore the feasibility of using recycled thermoplastic material as filament for fused deposition modeling technique. Design/methodology/approach In this study, the researchers fabricated fused filaments (in-house) for fused deposition modeling (FDM) technique of additive manufacturing from secondary recycled acrylonitrile butadiene styrene (ABS) by using a twin-screw extruder. After measuring the melt flow index of the secondary recycled ABS, the twin-screw extrusion parameters (rpm/speed of the screw, extrusion temperature and load) were varied to predict their influence on the various properties (rheological/mechanical/thermal) of the fabricated filaments. Experimental work was executed as per Taguchi’s L9 orthogonal array. Findings Thermal analysis performed to estimate the heat carrying capacity of recycled ABS highlighted that the heat capacity of ABS increases significantly from 0.28 J/g to 3.94 J/g during the heating cycle. The maximum value of peak strength and percentage break elongation for the fused filaments was investigated at 12.5 kg load, 2,250 C extrusion temperature and 70 rpm speed. Originality/value The filaments fabricated by recycling the polymeric waste has been successfully used in the FDM machine for the preparation of the three-dimensional printed tensile specimen.

Thermomechanical investigations of PEKK-HAp-CS composites

2019 ◽  
Vol 233 (11) ◽  
pp. 1196-1203
Author(s):  
Rupinder Singh ◽  
Gurchetan Singh ◽  
Jaskaran Singh ◽  
Ranvijay Kumar ◽  
Md Mustafizur Rahman ◽  
...  
Keyword(s):  
Melt Flow Index ◽  
Extrusion Process ◽  
Flow Index ◽  
Fused Deposition Modelling ◽  
Index Test ◽  
Melt Flow ◽  
Scanning Calorimetry ◽  
Fused Deposition ◽  
Ether Ketone ◽  
Input Variables

In this experimental study, a composite of poly-ether-ketone-ketone by reinforcement of hydroxyapatite and chitosan has been prepared for possible applications as orthopaedic scaffolds. Initially, different weight percentages of hydroxyapatite and chitosan were reinforced in the poly-ether-ketone-ketone matrix and tested for melt flow index in order to check the flowability of different compositions/proportions. Suitable compositions revealed by the melt flow index test were then taken forward for the extrusion of filament required for fused deposition modelling. For thermomechanical investigations, Taguchi-based design of experiments has been used with input variables in the extrusion process as follows: temperature, load applied and different composition/proportions. The specimens in the form of feedstock filament produced by the extrusion process were made to undergo tensile testing. The specimens were also inspected by differential scanning calorimetry and photomicrographs. Finally, the specimen showing the best performance from the thermomechanical viewpoint has been selected to extrude the filament for the fused deposition modelling process.

scholarly journals A Study on Melt Flow Index on Copper-ABS for Fused Deposition Modeling (FDM) Feedstock

2015 ◽  
Vol 773-774 ◽  
pp. 8-12 ◽  
Author(s):  
Noor Mu'izzah Ahmad Isa ◽  
Nasuha Sa'ude ◽  
M. Ibrahim ◽  
Saiful Manar Hamid ◽  
Khairu Kamarudin
Keyword(s):  
Injection Molding ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Melt Flow Index ◽  
Internal Force ◽  
Flow Index ◽  
Fused Deposition Modelling ◽  
Melt Flow ◽  
Volume Percentage ◽  
Fused Deposition

This paper presents of Polymer Matrix Composite (PMC) as feedstock used in Fused Deposition Modelling (FDM) machine. This study discussed on the development of a new PMC material by the injection molding machine. The material consist of copper powder filled in an acrylonitrile butadiene styrene (ABS), binder and surfactant material. The effect of metal filled in ABS and binder content was investigated experimentally by the Melt Flow Index (MFI) machine. Based on the result obtained, an increment of copper filled in ABS by volume percentage (vol. %) effected on melt flow index results. With highly filled copper in PMC composites increase the melt flow index results. It was concluded that, the propensity of the melt flow allow an internal force in PMC material through the injection molding and FDM machine.

Effects of micro particle reinforcement on mechanical properties of 3D printed parts

2018 ◽  
Vol 24 (1) ◽  
pp. 171-176 ◽  
Author(s):  
Ebubekir Çantı ◽  
Mustafa Aydın
Keyword(s):  
Mechanical Properties ◽  
Building Materials ◽  
Weight Ratio ◽  
Bending Test ◽  
Flow Index ◽  
Melt Flow ◽  
Particle Reinforcement ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose The purpose of this paper is to characterize the effects of different micro particle reinforcement with same weight ratio in acrylonitrile-butadiene-styrene (ABS) feed-stocks for 3D printing process. Design/methodology/approach In this study, composite filaments were produced by using a co-rotational twin screw extruder and used as building material to print samples in a commercial fused deposition modeling (FDM) 3D printer. The reinforcement particles, ZrB2 and Al, have different properties, including density, surface area, purity and particle morphology, and were expected to improve mechanical properties of 3D printed samples. Differential calorimetry scanning and melt flow index studies were applied on the materials to observe the change in glass transition temperatures and melt flow behaviors, respectively. Also, to evaluate the mechanical properties, tensile and three-point bending test were carried out. Fractured surfaces were characterized via energy-dispersive X-ray spectroscopy for validation of the reinforcements in the ABS matrix. Moreover, scanning electron microscope micrograph examination was conducted on the fractured surfaces to characterize fracture modes. Findings For 3D printed samples, a strain increase of at least 82.5 per cent was achieved by using micro particle reinforcement with a weight ratio of 1.5 per cent. Research limitations/implications Higher filler ratios of the reinforcement particles cause loss on the printability of the feed-stocks. Practical implications Reinforced ABS stands out as a possible solution to overcome robustness problems in FDM printing. Originality/value Even though the effects of printing parameters on the mechanical properties of 3D printed parts have been vastly studied in the literature, studies conducted on improvement of the building materials are limited. This paper proposes to create novel feed-stock materials for achieving printed parts with superior properties using polymer composites.

scholarly journals INVESTIGATIONS FOR ENHANCING THE APPLICATION DOMAIN OF FUSED DEPOSITION MODELLING PROCESS

2017 ◽  
Vol 46 (1) ◽  
pp. 36-40
Author(s):  
Rupinder Singh ◽  
Sunpreet Singh
Keyword(s):  
Signal To Noise Ratio ◽  
Research Work ◽  
Melt Flow Index ◽  
Flow Index ◽  
Fused Deposition Modelling ◽  
Application Domain ◽  
Melt Flow ◽  
Recent Past ◽  
Fused Deposition ◽  
Modelling Process

In the recent past, various studies have been reported on the development of in-house fused deposition modelling (FDM) filament, in order to increase the application domain of the process. But hitherto very less have reported on the effect of reinforcement type (such as: SiC, Al2O3 and Fe powder etc.) on the melt flow index (MFI) of the polymer matrix composite (PMC) to be used as FDM filament. In the present research work, an effort has beenmade to investigate the effect of selected proportions of filler, matrix (nylon-6) and extrusion load on the MFI of reinforced FDM filament. Experimental study was conducted on melt flow indexer (MFIer) as per ASTM-D1238-95 standard and signal to noise ratio was calculated to find out the effect of input process parameters on MFI of hybrid filament. It has been found that proportion of filler in matrix, type of filler material and extrusion load contributed about 16.62%, 1.23% and 76.72% respectively.

Experimental investigations for development of Nylon6-Al-Al2O3 alternative FDM filament

2016 ◽  
Vol 22 (2) ◽  
pp. 217-224 ◽  
Author(s):  
Kamaljit Singh Boparai ◽  
Rupinder Singh ◽  
Harwinder Singh
Keyword(s):  
Mechanical Properties ◽  
Thermal Stability ◽  
Composite Material ◽  
Mechanical Strength ◽  
Polymeric Materials ◽  
Flow Index ◽  
Manufacturing Cost ◽  
Screw Extruder ◽  
Content Type ◽  
Fused Deposition

Purpose The purpose of this paper is to fabricate Nylon6-Al-Al2O3-based alternative fused deposition modeling process (FDM) feedstock filament in place of commercial acrylonitrile butadiene styrene (ABS) filament (having required rheological and mechanical properties) for rapid manufacturing (RM) and rapid tooling (RT) applications. The detailed steps for fabrication of alternative FDM feedstock filament (as per field application) with relatively low manufacturing cost and tailor-made properties have been highlighted. Design/methodology/approach The rheological and mechanical suitability of nylon6-Al-Al2O3 feedstock filament has been investigated experimentally. The approach is to predict and incorporate essential properties such as flow rate, flexibility, stiffness and mechanical strength at processing conditions and compared with commercial ABS material. The proportions of various constituents have been varied to modify and improve rheological behavior and mechanical properties of alternative FDM feedstock filament. Findings The alternative material of feed stock filament was successfully developed and loaded in commercial FDM setup without changing any hardware and software. The result of study suggests that the newly developed composite material filament has relatively poor mechanical properties but have highly thermal stability and wear resistant as compared to ABS filament and hence can be used for tailor-made applications. Research limitations/implications In this work, no additive was added for improving the bond formation of metal and polymeric materials. The newly developed filament was prepared on single screw extruder. For more uniform mixing of metal and polymeric materials, further studies may be conducted on twin screw extruder. Also, for the present research work, the testing of newly developed filament has been limited up to mechanical testing, which may be extended to chemical and thermal analysis to understand thermal stability and degradation mechanism of newly developed composite material. Practical implications The proportion of filler material (Al-Al2O3) in Nylon6 matrix was set as a constraint, which was adjusted based upon melt flow index of original equipment manufacturer developed material (ABS), and temperature conditions were available at FDM nozzle (so that hardware and software system of commercial FDM setup need not to be altered). Originality/value The present approach outlined selection, processing, fabrication and testing procedure for alternate feedstock filament, which fulfills the necessary requirements of FDM process and has been customized for RT and RM applications. This work highlights mechanical strength evaluation of feedstock filament (which is necessary before the loading of material in FDM system). The potential applications of this investigation include RM of functional parts, tailor-made grinding tools for dentists and RT of metal matrix composite having complex geometry.

scholarly journals Melt Flow Index of Recycle ABS for Fused Deposition Modeling (FDM) Filament

2015 ◽  
Vol 773-774 ◽  
pp. 3-7 ◽  
Author(s):  
Nasuha Sa'ude ◽  
Khairu Kamarudin ◽  
Mustaffa Ibrahim ◽  
Mohd Halim Irwan Ibrahim
Keyword(s):  
Material Properties ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Melt Flow Index ◽  
Flow Index ◽  
Melt Flow ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Higher Temperature ◽  
Butadiene Styrene

This paper presents the melt flow index (MFI) of acrylonitrile butadiene styrene (ABS) and recycle ABS filament wire for Fused Deposition Modeling (FDM) machine. In this study, the effect of MFI on recycle ABS material was investigated experimentally based on the melting temperature, density, screw speed and material properties. The MFI result on ABS recycle in wire filament was investigated using Melt Indexer Machine (MIM). Based on the result obtained, it was found that, ABS recycle was increase the density and MFI results. It can be observed that, the higher temperature was melt the recycle ABS material through the MIM and extruder machine.

Mechanical, thermal and melt flow of aluminum-reinforced PA6/ABS blend feedstock filament for fused deposition modeling

2018 ◽  
Vol 24 (9) ◽  
pp. 1455-1468 ◽  
Author(s):  
Rupinder Singh ◽  
Ranvijay Kumar ◽  
IPS Ahuja
Keyword(s):  
Thermal Properties ◽  
Polymer Matrix ◽  
Friction Welding ◽  
Fused Deposition Modeling ◽  
Flow Index ◽  
Melt Flow ◽  
Content Type ◽  
Fused Deposition ◽  
Feed Stock ◽  
Deposition Modeling

Purpose This study aims to highlights the mechanical, thermal and melting behavior compatibility of aluminum (Al)-reinforced polyamide (PA) 6/acrylonitrile butadiene styrene (ABS)-based functional prototypes prepared using fused deposition modeling (FDM) from the friction welding point of view. Previous studies have highlighted the use of metallic/non-metallic fillers in polymer matrix for preparations of mechanically improved FDM feedstock filaments and functional prototypes. But hitherto, very less has been reported on fabrication of functional prototypes which fulfill the compatibility of two polymers for joining/welding-based applications. The compatibility of two dissimilar polymers enables the friction welding for maintenance applications. Design/methodology/approach The twin screw extrusion process has been used for mechanical mixing of metallic reinforcement in polymer matrix, and final blend of reinforced polymers in the form of extruded feed stock filament has been used on FDM for printing of functional prototypes (for friction welding). The methodology involves melt flow index (MFI) investigations, differential scanning calorimetry (DSC) investigations for thermal properties, tensile and hardness testing for mechanical properties and photo micrographic investigations for metallurgical properties on extruded samples. Findings It was observed that the reinforced ABS and PA6 polymers have better compatibility in the terms of similar melt flow, thermal properties and can lead to the better joint efficiency with friction welding. Originality/value In the present work composite feed stock filament composed of ABS and PA6 with reinforcement of Al powder has been successfully developed for preparation of functional prototype in friction welding applications.

scholarly journals Enhancement of mechanical, thermal and water uptake performance of TPU/jute fiber green composites via chemical treatments on fiber surface

e-Polymers ◽  
2020 ◽  
Vol 20 (1) ◽  
pp. 133-143 ◽  
Author(s):  
Tuffaha Fathe Salem ◽  
Seha Tirkes ◽  
Alinda Oyku Akar ◽  
Umit Tayfun
Keyword(s):  
Water Absorption ◽  
Water Uptake ◽  
Mechanical Test ◽  
Fiber Surface ◽  
Melt Flow Index ◽  
Jute Fiber ◽  
Morphological Properties ◽  
Flow Index ◽  
Melt Flow ◽  
Treatment Type

AbstractChopped jute fiber (JF) surfaces were modified using alkaline, silane and eco-grade epoxy resin. Surface characteristics of jute fibers were confirmed by FTIR and EDX analyses. JF filled polyurethane elastomer (TPU) composites were prepared via extrusion process. The effect of surface modifications of JF on mechanical, thermo-mechanical, melt-flow, water uptake and morphological properties of TPU-based eco-composites were investigated by tensile and hardness tests, dynamic mechanical analysis (DMA), melt flow index (MFI) test, water absorption measurements and scanning electron microscopy (SEM) techniques, respectively. Mechanical test results showed that silane and epoxy treated JF additions led to increase in tensile strength, modulus and hardness of TPU. Glass transition temperature (Tg) of TPU rose up to higher values after JF inclusions regardless of treatment type. Si-JF filled TPU exhibited the lowest water absorption among composites. Surface treated JFs displayed homogeneous dispersion into TPU and their surface were covered by TPU according to SEM micro-photographs.

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