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.

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.

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.

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.

Additive manufacturing using fine wire-based laser metal deposition

2019 ◽  
Vol 26 (3) ◽  
pp. 473-483
Author(s):  
Muhammad Omar Shaikh ◽  
Ching-Chia Chen ◽  
Hua-Cheng Chiang ◽  
Ji-Rong Chen ◽  
Yi-Chin Chou ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
High Precision ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
Laser Metal Deposition ◽  
Cross Sectional ◽  
Content Type ◽  
Fine Wire

Purpose Using wire as feedstock has several advantages for additive manufacturing (AM) of metal components, which include high deposition rates, efficient material use and low material costs. While the feasibility of wire-feed AM has been demonstrated, the accuracy and surface finish of the produced parts is generally lower than those obtained using powder-bed/-feed AM. The purpose of this study was to develop and investigate the feasibility of a fine wire-based laser metal deposition (FW-LMD) process for producing high-precision metal components with improved resolution, dimensional accuracy and surface finish. Design/methodology/approach The proposed FW-LMD AM process uses a fine stainless steel wire with a diameter of 100 µm as the additive material and a pulsed Nd:YAG laser as the heat source. The pulsed laser beam generates a melt pool on the substrate into which the fine wire is fed, and upon moving the X–Y stage, a single-pass weld bead is created during solidification that can be laterally and vertically stacked to create a 3D metal component. Process parameters including laser power, pulse duration and stage speed were optimized for the single-pass weld bead. The effect of lateral overlap was studied to ensure low surface roughness of the first layer onto which subsequent layers can be deposited. Multi-layer deposition was also performed and the resulting cross-sectional morphology, microhardness, phase formation, grain growth and tensile strength have been investigated. Findings An optimized lateral overlap of about 60-70% results in an average surface roughness of 8-16 µm along all printed directions of the X–Y stage. The single-layer thickness and dimensional accuracy of the proposed FW-LMD process was about 40-80 µm and ±30 µm, respectively. A dense cross-sectional morphology was observed for the multilayer stacking without any visible voids, pores or defects present between the layers. X-ray diffraction confirmed a majority austenite phase with small ferrite phase formation that occurs at the junction of the vertically stacked beads, as confirmed by the electron backscatter diffraction (EBSD) analysis. Tensile tests were performed and an ultimate tensile strength of about 700-750 MPa was observed for all samples. Furthermore, multilayer printing of different shapes with improved surface finish and thin-walled and inclined metal structures with a minimum achievable resolution of about 500 µm was presented. Originality/value To the best of the authors’ knowledge, this is the first study to report a directed energy deposition process using a fine metal wire with a diameter of 100 µm and can be a possible solution to improving surface finish and reducing the “stair-stepping” effect that is generally observed for wires with a larger diameter. The AM process proposed in this study can be an attractive alternative for 3D printing of high-precision metal components and can find application for rapid prototyping in a range of industries such as medical and automotive, among others.

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.

A review of melt extrusion additive manufacturing processes: II. Materials, dimensional accuracy, and surface roughness

2015 ◽  
Vol 21 (3) ◽  
pp. 250-261 ◽  
Author(s):  
Brian N. Turner ◽  
Scott A Gold
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Product Design ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Design Parameters ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Am Processes

Purpose – The purpose of this paper is to critically review the literature related to dimensional accuracy and surface roughness for fused deposition modeling and similar extrusion-based additive manufacturing or rapid prototyping processes. Design/methodology/approach – A systematic review of the literature was carried out by focusing on the relationship between process and product design parameters and the dimensional and surface properties of finished parts. Methods for evaluating these performance parameters are also reviewed. Findings – Fused deposition modeling® and related processes are the most widely used polymer rapid prototyping processes. For many applications, resolution, dimensional accuracy and surface roughness are among the most important properties in final parts. The influence of feedstock properties and system design on dimensional accuracy and resolution is reviewed. Thermal warping and shrinkage are often major sources of dimensional error in finished parts. This phenomenon is explored along with various approaches for evaluating dimensional accuracy. Product design parameters, in particular, slice height, strongly impact surface roughness. A geometric model for surface roughness is also reviewed. Originality/value – This represents the first review of extrusion AM processes focusing on dimensional accuracy and surface roughness. Understanding and improving relationships between materials, design parameters and the ultimate properties of finished parts will be key to improving extrusion AM processes and expanding their applications.

High-pressure jet-assisted turning of AISI 304: Experimental and multi-objective optimization approach

2017 ◽  
Vol 232 (6) ◽  
pp. 734-750 ◽  
Author(s):  
Sayed E Mirmohammadsadeghi ◽  
H Amirabadi
Keyword(s):  
Genetic Algorithm ◽  
Surface Roughness ◽  
High Pressure ◽  
Cutting Force ◽  
Process Parameters ◽  
Optimization Approach ◽  
Multi Objective Optimization ◽  
Aisi 304 ◽  
Multi Objective ◽  
304 Austenitic Stainless Steel

High-pressure jet-assisted turning is an effective method to decrease the cutting force and surface roughness. Efficiency of this process is related to application of proper jet pressure proportional to other process parameters. In this research, experiments were conducted for high-pressure jet-assisted turning in finishing AISI 304 austenitic stainless steel, based on response surface method. Against the expectations, the maximum jet pressure could not lead to the most efficient results, which means that applying high-pressure jet-assisted turning without considering optimal process parameters will diminish the improving effects of high-pressure jet assistance. For this purpose, two artificial neural networks were trained by genetic algorithm to model the surface roughness and cutting force based on the process parameters. Ultimately, nondominated sorting genetic algorithm was implemented for multi-objective optimization of process. Results demonstrated that the employed method provides an effective approach that indicates optimized range of process parameters.

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