A multi-criteria decision making method for vapor smoothening fused deposition modelling part

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sugavaneswarn M. ◽  
Prashanthi B. ◽  
John Rajan A.
Keyword(s):  
Decision Making ◽  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Orientation Angle ◽  
Multi Criteria Decision Making ◽  
Post Processing ◽  
Dimensional Error ◽  
Content Type ◽  
Fused Deposition

Purpose This paper aims to enhance the surface finish of the fused deposition modeling (FDM) part using the vapor smoothening (VS) post-processing method and to study the combined effect of FDM and VS process parameters on the quality of the part. Design/methodology/approach Analysis of variance method is used to understand the significance of the FDM and VS process parameters. Following this, the optimized parameter for multiple criteria response is reported using the technique for order preference by similarity to ideal solution. The process parameters alternatives are build orientation angle, build surface normal and exposure time and the criteria are surface roughness and dimensional error percentage. Findings The result observed contradicts the result reported on the independent parameter optimization of FDM and VS processes. There is a radical improvement in the surface finish on account of the coating process and an increase in the exposure time results in the decrease of the surface roughness. Minimum surface roughness of 0.11 µm is observed at 1,620 build angle and the least dimensional error of 0.01% is observed at build orientation angle 540. The impact of VS on the up-facing surface is different from the down-facing surface due to the removal of support material burrs and the exposure of the surface to vapor direction. Originality/value A study on the multi-criteria decision-making to ascertain the effect of post-processing on FDM component surface normal directed both to downward (build angle 0°–90°) and to upward (build angle 99°–180°) are reported for the first time in this article. The data reported for the post-processed FDM part at the build angle 0°–180° can be used as a guideline for selecting the optimal parameter and for assigning appropriate tolerance in the CAD model.

Multi-objective optimization of dimensional accuracy, surface roughness and hardness of hybrid investment cast components

2017 ◽  
Vol 23 (5) ◽  
pp. 845-857 ◽  
Author(s):  
Parlad Kumar Garg ◽  
Rupinder Singh ◽  
IPS Ahuja
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Multi Objective Optimization ◽  
Content Type ◽  
Multi Objective ◽  
Fused Deposition ◽  
Taguchi Design Of Experiments ◽  
Investment Cast

Purpose The purpose of this paper is to optimize the process parameters to obtain the best dimensional accuracy, surface finish and hardness of the castings produced by using fused deposition modeling (FDM)-based patterns in investment casting (IC). Design/methodology/approach In this paper, hip implants have been prepared by using plastic patterns in IC process. Taguchi design of experiments has been used to study the effect of six different input process parameters on the dimensional deviation, surface roughness and hardness of the implants. Analysis of variance has been used to find the effect of each input factor on the output. Multi-objective optimization has been done to find the combined best values of output. Findings The results proved that the FDM patterns can be used successfully in IC. A wax coating on the FDM patterns improves the surface finish and dimensional accuracy. The improved dimensional accuracy, surface finish and hardness have been achieved simultaneously through multi-objective optimization. Research limitations/implications A thin layer of wax is used on the plastic patterns. The effect of thickness of the layer has not been considered. Further research is needed to study the effect of the thickness of the wax layer. Practical implications The results obtained by the study would be helpful in making decisions regarding machining and/or coating on the parts produced by this process. Originality/value In this paper, multi-objective optimization of dimensional accuracy, surface roughness and hardness of hybrid investment cast components has been performed.

Investigations for improving the surface finish of FDM based ABS replicas by chemical vapor smoothing process: a case study

2017 ◽  
Vol 37 (1) ◽  
pp. 13-21 ◽  
Author(s):  
Jaspreet Singh ◽  
Rupinder Singh ◽  
Harwinder Singh
Keyword(s):  
Process Parameters ◽  
Surface Finish ◽  
Research Work ◽  
Chemical Vapor ◽  
Fused Deposition Modelling ◽  
Post Processing ◽  
Processing Stage ◽  
Content Type ◽  
Fused Deposition

Purpose This research work aims to make an effort to investigate the effect of fused deposition modelling (FDM) process parameters on the surface finish of acrylonitrile butadiene styrene (ABS) replicas (as pre-processing stage), followed by chemical vapor smoothing (CVS) process (as a post-processing stage) as a case study. Design/methodology/approach The Taguchi L18 orthogonal array has been used for optimizing process parameters of FDM and CVS processes. Findings This study highlights that orientation and part density, and the interaction between these two have a significant effect on the surface finish at the pre-processing stage of FDM. However, after post-processing with CVS, there is hardly any influence of pre-processing FDM parameters. Originality/value The study highlights that for improving the productivity of the FDM process, the parametric optimization of process may be made on the basis of production cost and time in place of surface finish of ABS replicas. The results obtained have been verified by performing the confirmation experiments.

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 cold vapour treatment on geometric accuracy of fused deposition modelling parts

2017 ◽  
Vol 23 (6) ◽  
pp. 1226-1236 ◽  
Author(s):  
Ashu Garg ◽  
Anirban Bhattacharya ◽  
Ajay Batish
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Fused Deposition Modelling ◽  
Curved Surfaces ◽  
Geometric Accuracy ◽  
Content Type ◽  
Fused Deposition ◽  
Cold Vapour ◽  
Side Face ◽  
Functional Components

Purpose The purpose of this paper is to investigate the influence of low-cost chemical vapour treatment process on geometric accuracy and surface roughness of different curved and freeform surfaces of fused deposition modelling (FDM) specimens build at different part building orientations. Design/methodology/approach Parts with different primitive and curved surfaces are designed and modelled to build at three different part orientations along X orientation (vertical position resting on side face), Y orientation (horizontal position resting on base) and Z orientation (upright position). Later, the parts are post-processed by cold vapours of acetone. Geometric accuracy and surface roughness are measured both before and after the chemical treatment to investigate the change in geometric accuracy, surface roughness of FDM parts. Findings The results indicate that surface roughness is reduced immensely after cold vapour treatment with minimum variation in geometric accuracy of parts. Parts build vertically over its side face (X orientation) provides the overall better surface finish and geometric accuracy. Originality/value The present study provides an approach of post-built treatment for FDM parts and observes a significant improvement in surface finish of the components. The present approach of post-built treatment can be adopted to enhance the surface quality as well as to achieve desired geometric accuracy for different primitive, freeform/curved surfaces of FDM samples suitable for functional components as well as prototypes.

Surface enhancement of FDM patterns to be used in rapid investment casting for making medical implants

2019 ◽  
Vol 25 (5) ◽  
pp. 904-914 ◽  
Author(s):  
Vivek Kumar Tiwary ◽  
Arunkumar P. ◽  
Anand S. Deshpande ◽  
Nikhil Rangaswamy
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Finish ◽  
Investment Casting ◽  
Chemical Treatment ◽  
Medical Implants ◽  
Post Processing ◽  
Content Type ◽  
Casting Technique ◽  
Processing Treatment

Purpose Due to intrinsic limitations, fused deposition modelling (FDM) products suffer from the bad surface finish and inaccurate dimensional accuracies restricting its usage in many applications. Hence, there is a need for processing polymer patterns before, during and after their productions. This paper aims to highlight the importance of pre- and post-processing treatments on the FDM-based acrylonitrile butadiene styrene patterns improving its surface quality so, that it can be used in rapid investment casting process for making medical implants and other high precision components. Design/methodology/approach As a part of pre-processing treatment, the machine parameters affecting the surface quality were identified and optimised using design of experiments. The patterns developed after the first stage of optimisation were given different post-processing treatments, which included vapour smoothening, chemical treatment and sand paper polishing. The results were compared and the best ones were used for making patterns for making medical implants via rapid investment casting technique. The surface quality was checked while the dimensional changes happening during the stages of this hybrid technique were recorded using a three-dimensional optical scanner. Findings The surface roughness of the FDM based ABS patterns reduced from 21.63 to 14.40 µm with pre-processing treatments. Chemical treatment (post-processing treatment) turned to be the most suitable technique for reducing the surface roughness further down to 0.30 µm. Medical implants that used these pre- and post-processing treatments gave an average surface roughness of 0.68 µm. Cost and lead time comparisons showed that rapid investment casting technique can be a better method for low volume, customised and with specific requirements. Originality/value FDM parts/medical implants produced by rapid investment casting technique suffer from the inferior surface finish and inaccurate dimensional accuracies limiting its applications. A systematic approach to overcome this issue is presented in this research paper. This will directly help the end users and the manufacturers of medical implants, wherein, better surface finish and dimensionally accurate components are expected.

Pre and post processing techniques to improve surface characteristics of FDM parts: a state of art review and future applications

2017 ◽  
Vol 23 (3) ◽  
pp. 495-513 ◽  
Author(s):  
Jasgurpreet Singh Chohan ◽  
Rupinder Singh
Keyword(s):  
Surface Finish ◽  
Low Cost ◽  
Dimensional Accuracy ◽  
Surface Characteristics ◽  
Processing Parameters ◽  
Surface Finishing ◽  
Post Processing ◽  
Content Type ◽  
Fused Deposition ◽  
Processing Techniques

Purpose The purpose of this paper is to review the various pre-processing and post-processing approaches used to ameliorate the surface characteristics of fused deposition modelling (FDM)-based acrylonitrile butadiene styrene (ABS) prototypes. FDM being simple and versatile additive manufacturing technique has a calibre to comply with present need of tailor-made and cost-effective products with low cycle time. But the poor surface finish and dimensional accuracy are the primary hurdles ahead the implementation of FDM for rapid casting and tooling applications. Design/methodology/approach The consequences and scope of FDM pre-processing and post-processing parameters have been studied independently. The comprehensive study includes dominance, limitations, validity and reach of various techniques embraced to improve surface characteristics of ABS parts. The replicas of hip implant are fabricated by maintaining the optimum pre-processing parameters as reviewed, and a case study has been executed to evaluate the capability of vapour smoothing process to enhance surface finish. Findings The pre-processing techniques are quite deficient when different geometries are required to be manufactured within limited time and required range of surface finish and accuracy. The post-processing techniques of surface finishing, being effective disturbs the dimensional stability and mechanical strength of parts thus incapacitates them for specific applications. The major challenge for FDM is the development of precise, automatic and controlled mass finishing techniques with low cost and time. Research limitations/implications The research assessed the feasibility of vapour smoothing technique for surface finishing which can make consistent castings of customized implants at low cost and shorter lead times. Originality/value The extensive research regarding surface finish and dimensional accuracy of FDM parts has been collected, and inferences made by study have been used to fabricate replicas to further examine advanced finishing technique of vapour smoothing.

Multi-response optimization for machining GFRP composites using GRA and DFA

2018 ◽  
Vol 14 (3) ◽  
pp. 482-496 ◽  
Author(s):  
Naresh Neeli ◽  
M.P. Jenarthanan ◽  
G. Dileep Kumar
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Feed Rate ◽  
Fibre Orientation ◽  
Orientation Angle ◽  
Helix Angle ◽  
Spindle Speed ◽  
Gfrp Composites ◽  
Content Type ◽  
Fibre Orientation Angle

Purpose The purpose of this paper is to optimise the process parameters, namely, fibre orientation angle, helix angle, spindle speed, and feed rate in milling of glass fibre-reinforced plastic (GFRP) composites using grey relational analysis (GRA) and desirability function analysis (DFA). Design/methodology/approach In this work, experiments were carried out as per the Taguchi experimental design and an L27 orthogonal array was used to study the influence of various combinations of process parameters on surface roughness and delamination factor. As a dynamic approach, the multiple response optimisation was carried out using GRA and DFA for simultaneous evaluation. These two methods are best suited for multiple criteria evaluation and are also not much complicated. Findings The process parameters were found optimum at a fibre orientation angle of 15°, helix angle of 25°, spindle speed of 6,000 rpm, and a feed rate of 0.04 mm/rev. Analysis of variance was employed to classify the significant parameters affecting the responses. The results indicate that the fibre orientation angle is the most significant parameter preceded by helix angle, feed rate, and spindle speed for GFRP composites. Originality/value An attempt to optimise surface roughness and delamination factor together by combined approach of GRA and DFA has not been previously done.

Experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling

2020 ◽  
Vol 26 (9) ◽  
pp. 1535-1554
Author(s):  
Swapnil Vyavahare ◽  
Shailendra Kumar ◽  
Deepak Panghal
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Layer Thickness ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Fused Deposition Modelling ◽  
Content Type ◽  
Build Orientation ◽  
Fused Deposition ◽  
Significant Process

Purpose This paper aims to focus on an experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling (FDM) technique of additive manufacturing. The fabricated parts of acrylonitrile butadiene styrene (ABS) material have pyramidal and conical features. Influence of five process parameters of FDM, namely, layer thickness, wall print speed, build orientation, wall thickness and extrusion temperature is studied on response characteristics. Furthermore, regression models for responses are developed and significant process parameters are optimized. Design/methodology/approach Comprehensive experimental study is performed using response surface methodology. Analysis of variance is used to investigate the influence of process parameters on surface roughness, dimensional accuracy and time of fabrication in both outer pyramidal and inner conical regions of part. Furthermore, a multi-response optimization using desirability function is performed to minimize surface roughness, improve dimensional accuracy and minimize time of fabrication of parts. Findings It is found that layer thickness and build orientation are significant process parameters for surface roughness of parts. Surface roughness increases with increase in layer thickness, while it decreases initially and then increases with increase in build orientation. Layer thickness, wall print speed and build orientation are significant process parameters for dimensional accuracy of FDM parts. For the time of fabrication, layer thickness and build orientation are found as significant process parameters. Based on the analysis, statistical non-linear quadratic models are developed to predict surface roughness, dimensional accuracy and time of fabrication. Optimization of process parameters is also performed using desirability function. Research limitations/implications The present study is restricted to the parts of ABS material with pyramidal and conical features only fabricated on FDM machine with delta configuration. Originality/value From the critical review of literature it is found that some researchers have made to study the influence of few process parameters on surface roughness, dimensional accuracy and time of fabrication of simple geometrical parts. Also, regression models and optimization of process parameters has been performed for simple parts. The present work is focussed on studying all these aspects in complicated geometrical parts with pyramidal and conical features.

scholarly journals Taguchi S/N and TOPSIS Based Optimization of Fused Deposition Modelling and Vapor Finishing Process for Manufacturing of ABS Plastic Parts

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5176
Author(s):  
Jasgurpreet Singh Chohan ◽  
Raman Kumar ◽  
TH Bhatia Singh ◽  
Sandeep Singh ◽  
Shubham Sharma ◽  
...  
Keyword(s):  
Surface Roughness ◽  
New Product Development ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Orientation Angle ◽  
Fused Deposition Modelling ◽  
Strength Increase ◽  
Major Barrier ◽  
Practical Applications ◽  
Fused Deposition

Despite several additive manufacturing techniques are commercially available in market, Fused Deposition Modeling (FDM) is increasingly used by researchers and engineers for new product development. FDM is an established process with a plethora of advantages, but the visible surface roughness (SR), being an intrinsic limitation, is major barrier against utilization of fabricated parts for practical applications. In the present study, the chemical finishing method, using vapour of acetone mixed with heated air, is being used. The combined impact of orientation angle, finishing temperature and finishing time has been studied using Taguchi and ANOVA, whereas multi-criteria optimization is performed using the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). The surface finish was highly responsive to increase in temperature while orientation angle of 0° yielded maximum strength; increase in finishing time led to weight gain of FDM parts. As the temperature increases, the percentage change in surface roughness increases as higher temperature assists the melt down process. On the other hand, anisotropic behaviour plays a major role during tensile testing. The Signal-to-noise (S/N) ratio plots, and ANOVA results indicated that surface finish is directly proportionate to finishing time because a longer exposure results in complete layer reflowing and settlement.

Investigations for dimensional accuracy of AMC prepared by using Nylon6-Al-Al2O3 reinforced FDM filament in investment casting

2016 ◽  
Vol 22 (3) ◽  
pp. 445-455 ◽  
Author(s):  
Sunpreet Singh ◽  
Rupinder Singh
Keyword(s):  
Process Parameters ◽  
Surface Finish ◽  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Flow Index ◽  
Intermediate Step ◽  
Content Type ◽  
Fused Deposition ◽  
Barrel Finishing

Purpose This paper aims to investigate the dimensional accuracy of aluminium (Al) matrix composites (AMCs) prepared by using an alternative reinforced fused deposition modeling (FDM)-based sacrificial patterns in investment casting (IC) process. Further in this work, a barrel finishing (BF) process has been introduced as an intermediate step for the improvement of surface finish of sacrificial patterns and to study the effect of BF process parameters on dimensional features of the casted AMCs. In the present research, an effort has been made to ascertain the capability/producibility of the proposed route for obtaining good geometrical tolerances. Design/methodology/approach Alternative reinforced FDM filaments were developed using single screw extruder whose melt flow index was matched with the commercial acrylonitrile–butadiene–styrene filament. IC sacrificial patterns, fabricated on existing FDM system without making any change in its hardware/software, were barrel finished for improving the surface finish. The effect of FDM, BF and IC process parameters, namely, type of filament, volume of CAD-based cubical pattern, pattern density, BF time, BF media weight and numbers of IC slurry layers, was studied using Taguchi L18 OA approach. Findings Dimensional accuracy of casted AMCs developed was optimized successfully using Taguchi L18 orthogonal array. Optical microscopic analysis made on the castings highlighted the presence of Al2O3 particles which will result into the improvement of mechanical and tribological properties. International tolerance grade of cast AMCs was calculated and found acceptable as per ISO standard UNI-EN-20286-I (1995). Further, there are strong possibilities of process to be under statistical control at proposed settings. Originality/value The paper describes a new route for the development of AMC. The effect of FDM, BF and IC process parameters on dimensional accuracy of AMCs developed is also highlighted in the present research.

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