Influence of processing parameters on creep and recovery behavior of FDM manufactured part using definitive screening design and ANN

2017 ◽  
Vol 23 (6) ◽  
pp. 998-1010 ◽  
Author(s):  
Omar Ahmed Mohamed ◽  
Syed Hasan Masood ◽  
Jahar Lal Bhowmik
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Air Gap ◽  
Content Type ◽  
Screening Design ◽  
Definitive Screening ◽  
Raster Angle ◽  
Road Width ◽  
Recoverable Compliance ◽  
The Relationship

Purpose The purpose of this paper is to investigate the effect of process parameters of fused deposition modelling (FDM) 3D printing process on viscoelastic responses (creep compliance and recoverable compliance) of FDM built parts using a novel experimental design technique. Design/methodology/approach As part of the process characterization, a recently developed class of three-level design methodology – definitive screening design (DSD) – was used in this study to fit a second-order polynomial regression model. Artificial neural network (ANN) was also used to determine the optimal process parameters to improve creep compliance and recoverable compliance. The relationship between layer thickness, air gap, raster angle, build orientation, road width, number of contours and creep performance of FDM fabricated part was thereafter established empirically. Scanning electron microscope (SEM) is used to examine and characterize the morphology of the structures for some samples. Findings This study found that the creep resistance of FDM-manufactured part is significantly influenced by layer thickness, air gap, raster angle and number of contours and it can be improved by optimizing the settings of the selected parameters. The relationship between FDM process parameters and creep properties was determined, with the best creep performance observed by using 0.127 mm of layer thickness, zero air gap, zero raster angle, build orientation of 17.188°, road width of 0.4572 mm and 10 contours. Finally, the result is verified by confirmation experiments. The results prove that a DSD is a very effective design in characterizing the influence of process parameters on creep properties of FDM-built part at the lowest cost. Originality/value The originality of this paper lies in characterizing and optimizing the effect of process parameters on creep performance of FDM manufactured part that has not been studied in all previous studies. The paper highlights, for the first time, how the application of DSD can overcome most of the limitations encountered in the conventional techniques. This study can be used as a guide to the different additive manufacturing users of various industries and the results provide a good technical database on how FDM process parameters influence the creep performance of manufactured parts.

OPTIMIZATION OF PROCESS PARAMETERS IN FUSED DEPOSITION MODELING USING WEIGHTED PRINCIPAL COMPONENT ANALYSIS

2011 ◽  
Vol 10 (02) ◽  
pp. 241-259 ◽  
Author(s):  
ANOOP KUMAR SOOD ◽  
VEDANSH CHATURVEDI ◽  
SAURAV DATTA ◽  
SIBA SANKAR MAHAPATRA
Keyword(s):  
Principal Component Analysis ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Principal Component ◽  
Air Gap ◽  
Fused Deposition ◽  
Raster Angle ◽  
Deposition Modeling ◽  
Single Response

Fused deposition modeling (FDM) is a process by which functional parts can be produced rapidly through deposition of fused layers of material according to a numerically defined cross-sectional geometry. Literature suggests that process parameters largely influence on quality characteristics of rapid prototyping (RP) parts. A functional part is subjected to different loading conditions in actual practice. Therefore, process parameters need to be determined in such a way that they collectively optimize more than one response simultaneously. To address this issue, effect of important process parameters viz., layer thickness, orientation, raster angle, raster width, and air gap have been studied. The responses considered in this study are mechanical property of FDM produced parts such as tensile, bending and impact strength. The multiple responses are converted into a single response using principal component analysis (PCA) so that influence of correlation among the responses can be eliminated. Resulting single response is nothing but the weighted sum of three principal components that explain almost hundred percent of variation. The experiments have been conducted in accordance with Taguchi's orthogonal array to reduce the experimental runs. The results indicate that all the factors such as layer thickness, orientation, raster angle, raster width and air gap and interaction between layer thickness and orientation significantly influence the response. Optimum parameter settings have been identified to simultaneously optimize three responses. The mechanism of failure is explained with the help of SEM micrographs.

Investigating impact of five build parameters on the maximum flexural force in FDM specimens – a definitive screening design approach

2017 ◽  
Vol 23 (6) ◽  
pp. 1088-1098 ◽  
Author(s):  
Ognjan Luzanin ◽  
Vera Guduric ◽  
Ivan Ristic ◽  
Simon Muhic
Keyword(s):  
Layer Thickness ◽  
Extrusion Temperature ◽  
Quadratic Term ◽  
Extrusion Speed ◽  
Content Type ◽  
Screening Design ◽  
Definitive Screening ◽  
The Impact ◽  
Definitive Screening Design ◽  
Deposition Angle

Purpose The purpose of this study was to examine the impact of five key build parameters – layer thickness, deposition angle, infill, extrusion speed and extrusion temperature, and their interactions – on the maximum flexural force in specimens which are made of polylactic acid (PLA). Design/methodology/approach Through a previous study on the flexural properties of PLA specimens, a statistically significant effect of layer thickness was indicated, requiring further experimentation to establish the values of quadratic term in the model, as well as to perform optimization. Instead of performing a conventional Central Composite Design, a novel, definitive screening design (DSD) was used as statistical method. DSD allowed the reduction of the number of runs required for optimization while minimizing aliasing. Findings Significance of deposition angle and infill as main effects was established. Moreover, significant two-way interactions between infill/layer thickness and infill/extrusion speed were detected and discussed. The optimization procedure showed that minimum level of deposition angle, maximum levels of extrusion speed and infill and near mid-level of layer thickness yield maximum flexural force. Research limitations/implications In this study, the three levels of infill were 0.1, 0.2 and 0.3, which corresponds to 10, 20 and 30 per cent of infill, respectively. In everyday practice, infill is usually kept within this range since it allows time-efficiency, i.e. significant reduction of build time. Though, unsurprisingly, higher infill is positively correlated with flexural strength, this study provides practical directions for optimal selection of other key parameters when working with low infill values. Social implications Optimal 3D printing with low infill can contribute to lower material waste and pollution, while PLA plastic’s biodegradability remains high on the environment protection agenda. Originality/value According to available literature, no previous studies have investigated the FDM extrusion of PLA material using a combination of low infill, deposition angle, layer thickness, extrusion speed and extrusion temperature.

Investigation of effect of process variable on dimensional accuracy of FDM component using response surface methodology

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nagendra Kumar Maurya ◽  
Manish Maurya ◽  
Shashi Prakash Dwivedi ◽  
Ashish Kumar Srivastava ◽  
Ambuj Saxena ◽  
...  
Keyword(s):  
Response Surface Methodology ◽  
Layer Thickness ◽  
Process Parameters ◽  
Dimensional Accuracy ◽  
Percentage Error ◽  
Content Type ◽  
Average Percentage ◽  
Raster Angle ◽  
Radial Dimension ◽  
Average Percentage Error

Purpose Nowadays, rapid prototyping is emerging as end use product in low volume. The accuracy of the fabricated components depends on various process parameters. Process parameters used in this investigation are layer thickness (150, 200 and 250 µm), infill pattern (linear, hexagonal and star fill), raster angle (0°, 45° and 90°) and infill density (40, 60 and 80%). Linear and radial dimension of knuckle joint are selected for the response factor. Design/methodology/approach The experiments are design by using response surface methodology (RSM). Four design variables at three levels are used to examine their influence on percentage error in linear dimension and radial dimension of the component. A prototype Knuckle joint is selected as component. Minitab-14 software is used for the design of experiments. Findings Experimental measure data is analyzed by using “smaller is better” quality characteristics. A regression model for the forecasting of percentage error in linear and radial dimension is developed. The developed model is within precision range. The optimum level of process for linear and radial dimensions are obtained: layer thickness of 150 µm, Infill pattern of linear, Raster angle of 90° and infill density of 40%. Research limitations/implications It proves that both the mathematical model is significant and can be able to approximate the desired output value close to the accurate dimensions. While comparing the calculated F-values for both linear and radial dimension with the standard table (F-table, 0.05), it is found that at the given set of degree of freedom the standard F-values (6.61) is lower for that regression, linear, square and interaction source of the predicted model, for which p-values have already less than 0.05. It is desirable for significant process parameters. Practical implications The dimensional accuracy with respect to average percentage error of FDM produced knuckle joint is successfully examined. The effect of process parameters, namely, layer thickness, infill pattern, raster angle and infill density on average percentage error was investigated by RSM and analysis of variance table. Social implications The novelty of this work lies in the fact that only few studies are available in archival literature related to influence of these process parameters on percentage error in linear and radial dimension for Polycarbonate (PC) material. Originality/value The novelty of this work lies in the fact only few studies are available in archival literature related to influence of these process parameters on percentage error in linear and radial dimension for Polycarbonate (PC) material.

Optimization of build orientation in FFF using response surface methodology and posterior-based method

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mohammad Javad Hooshmand ◽  
Saeed Mansour ◽  
Amin Dehghanian
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Empirical Models ◽  
High Quality ◽  
Content Type ◽  
Build Orientation ◽  
Build Time ◽  
Raster Angle ◽  
Quality Surface ◽  
Response Variables

Purpose The advancement of additive manufacturing technologies has resulted in producing parts of high quality and reduced manufacturing time. This paper aims to achieve a simultaneous optimal solution for build time and surface roughness as the output data and also to find the best values for the input data consisting of build orientation, extrusion width, layer thickness, infill percentage and raster angle. Design/methodology/approach For this purpose, the effects of process parameters on the response variables were investigated by the design of experiments approach to develop empirical models using response surface methodology. The experimental parts of this research were conducted using an inexpensive and locally assembled fused filament fabrication (FFF) machine. A total of 50 runs for 4 different geometries, namely, cylinder, prism, 3DBenchy and twist gear vase, were performed using the rotatable central composite design, and each process parameters were investigated in two levels to develop empirical models. Also, a novel optimization method, namely, the posterior-based method, was accomplished to find the best values for the response variables. Findings The results demonstrated that not only the build orientation and layer thickness have notable effects on both response variables but also build time is dependent on extrusion width and infill percentage. Low infill percentage and high extrusion width resulted in increasing build time. By reducing layer thickness and infill percentage while increasing extrusion width, parts of high-quality surface finish and reduced built time were produced. Optimum process parameters were found to be of build direction of 0°, extrusion width of 0.61 mm, layer thickness of 0.22 mm, infill percentage of 20% and raster angle of 0°. Originality/value Through the developed empirical models and by minimizing build orientation and layer thickness, and also considerations for process parameters, parts of high-quality surface finish and reduced built time could be produced on FFF machines. To compensate for increased build time because of reduction in layer thickness, extrusion width and infill percentage must have their maximum and minimum value, respectively.

Open hole tensile testing of 3D printed parts using in-house fabricated PLA filament

2020 ◽  
Vol 26 (1) ◽  
pp. 21-31 ◽  
Author(s):  
Harshit K. Dave ◽  
Ashish R. Prajapati ◽  
Shilpesh R. Rajpurohit ◽  
Naushil H. Patadiya ◽  
Harit K. Raval
Keyword(s):  
Tensile Strength ◽  
Layer Thickness ◽  
Process Parameters ◽  
Geometrical Shape ◽  
Content Type ◽  
Fused Deposition ◽  
Open Hole ◽  
Raster Angle ◽  
3D Printed ◽  
The Impact

Purpose Fused deposition modeling (FDM) is being increasingly used in automotive and aerospace industries because of its ability to produce specimens having difficult geometrical shape. However, owing to lack of critical information regarding the reliability and mechanical properties of FDM-printed parts at various designs, the use of 3D printed parts in these industries is limited. Therefore, the purpose of this paper is to investigate the impact of process parameters of FDM on the tensile strength of open-hole specimen printed using in-house-fabricated polylactic acid (PLA). Design/methodology/approach In the present study, three process parameters, namely, raster angle, layer thickness and raster width, are selected for investigation of tensile strength. To produce the tensile specimens in the FDM machine, the PLA filament is used which is fabricated from PLA granules using a single-screw extruder. Further, the experimental values are measured and critically analysed. Failure modes under tests are studied using scanning electron microscopy (SEM). Findings Results indicate that the raster angle has a significant effect on the tensile strength of open-hole tensile specimen. Specimens built with 0° raster angle, 200-µm layer thickness and 500-µm raster width obtained maximum tensile strength. Originality/value In this work, a new concept of testing a plate that has a rectangular shape and a circular hole at the centre is tested. Open-hole tensile test standard ASTM D5766 has been implemented for the first time for the FDM process.

Effect of Tool Path Parameters on Part Porosity in Fused Filament Fabrication of Poly(Ethylene-co-Trimethylene Terephthalate)

2018 ◽  
Vol 382 ◽  
pp. 99-103
Author(s):  
Robert Bail
Keyword(s):  
Layer Thickness ◽  
Tool Path ◽  
Air Gap ◽  
Engineering Material ◽  
Fused Filament Fabrication ◽  
Additive Fabrication ◽  
Food Applications ◽  
Road Width ◽  
Trimethylene Terephthalate ◽  
Poly Ethylene

Poly(ethylene-co-trimethylene terephthalate) is an engineering material that has recently gained attention for use in fused filament fabrication (FFF). Although the properties of this thermoplastic are well suited for this process, the porosity of the components made remains a barrier to wider use of this approach in the additive fabrication of tight components for medical and food applications. This study investigated the effects of four tool path parameters of the FFF process – road width, air gap, layer thickness, and outer contours – on the void fraction in the structures made. It was revealed that the porosity was reduced from above 9% to below 2% when the extrusion rate was increased from initially 5.00 mm3/s to at least 5.75 mm3/s. A similar outcome was observed when a negative air gap between two adjacent strands of -15% or less was applied. In addition, these results were obtained without extending the print times. By contrast, altering the layer thickness and number of contours had only marginal or no effects on part porosity.

scholarly journals Controlling the porosity of 316L stainless steel parts manufactured via the powder bed fusion process

2019 ◽  
Vol 25 (1) ◽  
pp. 162-175 ◽  
Author(s):  
Abdullah AlFaify ◽  
James Hughes ◽  
Keith Ridgway
Keyword(s):  
Stainless Steel ◽  
Layer Thickness ◽  
Exposure Time ◽  
Process Parameters ◽  
Pulsed Laser ◽  
Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Point Distance ◽  
Part Density

Purpose The pulsed-laser powder bed fusion (PBF) process is an additive manufacturing technology that uses a laser with pulsed beam to melt metal powder. In this case, stainless steel SS316L alloy is used to produce complex components. To produce components with acceptable mechanical performance requires a comprehensive understanding of process parameters and their interactions. This study aims to understand the influence of process parameters on reducing porosity and increasing part density. Design/methodology/approach The response surface method (RSM) is used to investigate the impact of changing critical parameters on the density of parts manufactured. Parameters considered include: point distance, exposure time, hatching distance and layer thickness. Part density was used to identify the most statistically significant parameters, before each parameter was analysed individually. Findings A clear correlation between the number and shape of pores and the process parameters was identified. Point distance, exposure time and layer thickness were found to significantly affect part density. The interaction between these parameters also critically affected the development of porosity. Finally, a regression model was developed and verified experimentally and used to accurately predict part density. Research limitations/implications The study considered a range of selected parameters relevant to the SS316L alloy. These parameters need to be modified for other alloys according to their physical properties. Originality/value This study is believed to be the first systematic attempt to use RSM for the design of experiments (DOE) to investigate the effect of process parameters of the pulsed-laser PBF process on the density of the SS316L alloy components.

Tailoring physico-mechanical properties and rheological behavior of ABS filaments for FDM via blending with SEBS TPE

2020 ◽  
Vol 26 (10) ◽  
pp. 1687-1700
Author(s):  
Mozhgan Sayanjali ◽  
Amir Masood Rezadoust ◽  
Foroud Abbassi Sourki
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
3D Printing ◽  
Impact Strength ◽  
Layer Thickness ◽  
Melt Mixing ◽  
Content Type ◽  
Build Orientation ◽  
Raster Angle ◽  
The Impact

Purpose This paper aims to focus on the development of the three-dimensional (3D) printing filaments based on acrylonitrile butadiene styrene (ABS) copolymer and styrene-ethylene/butylene-styrene (SEBS) block copolymer, with tailored viscoelastic properties and controlled flow during the 3D printing process. Design/methodology/approach In this investigation, ABS was blended with various amounts of SEBS via a melt mixing process. Then the ABS/SEBS filaments were prepared by a single-screw extruder and printed by the FDM method. The rheological properties were determined using an MCR 501 from Anton-Paar. The melt flow behavior of ABS/SEBS filaments was determined. The morphology of the filaments was studied by scanning electron microscope and the mechanical (tensile and impact) properties, surface roughness and void content of printed samples were investigated. Findings The rheological results can accurately interpret what drives the morphology and mechanical properties’ changes in the blends. The impact strength, toughness, elongation-at-break and anisotropy in mechanical properties of ABS samples were improved concurrently by adding 40 Wt.% of SEBS. The optimal tensile properties of blend containing 40 Wt.% SEBS samples were obtained at −45°/+45° raster angle, 0.05 mm layer thickness and XYZ build orientation. Optimized samples showed an 890% increase in elongation compared to neat ABS. Also, the impact strength of ABS samples showed a 60% improvement by adding 40 Wt.% SEBS. Originality/value The paper simultaneously evaluates the effects of material composition and 3D printing parameters (layer thickness, raster angle and build orientation) on the rheology, morphology, mechanical properties and surface roughness. Also, a mechanical properties comparison between printed samples and their compression-molded counterpart was conducted.

Role of process parameters during additive manufacturing by direct metal deposition of Inconel 718

2017 ◽  
Vol 23 (5) ◽  
pp. 919-929 ◽  
Author(s):  
Bo Chen ◽  
Jyoti Mazumder
Keyword(s):  
Additive Manufacturing ◽  
Cooling Rate ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Processing Parameters ◽  
Forming Quality ◽  
Content Type ◽  
Forming Characteristics ◽  
The Relationship

Purpose The aim of this research is to study the influence of laser additive manufacturing process parameters on the deposit formation characteristics of Inconel 718 superalloy, the main parameters that influence the forming characteristics, the cooling rate and the microstructure were studied. Design/methodology/approach Orthogonal experiment design method was used to obtain different deposit shape and microstructure using different process parameters by multiple layers deposition. The relationship between the processing parameters and the geometry of the cladding was analyzed, and the dominant parameters that influenced the cladding width and height were identified. The cooling rates of different forming conditions were obtained by the secondary dendrite arm spacing (SDAS). Findings The microstructure showed different characteristics at different parts of the deposit. Cooling rate of different samples were obtained and compared by using the SDAS, and the influence of the process parameters to the cooling rate was analyzed. Finally, micro-hardness tests were done, and the results were found to be in accordance with the micro-structure distribution. Originality/value Relationships between processing parameters and the forming characteristics and the cooling rates were obtained. The results obtained in this paper will help to understand the relationship between the process parameters and the forming quality of the additive manufacturing process, so as to obtain the desired forming quality by appropriate parameters.

Process–Property Relationships for Fused Filament Fabrication on Preexisting Polymer Substrates

2018 ◽  
Vol 140 (8) ◽  
Author(s):  
Harry A. Pierson ◽  
Bharat Chivukula
Keyword(s):  
Surface Roughness ◽  
Bond Strength ◽  
Layer Thickness ◽  
Process Parameters ◽  
Optimal Parameter ◽  
Fused Filament Fabrication ◽  
Highly Sensitive ◽  
Raster Angle ◽  
Process Property ◽  
Five Axis

Recent advances in fused filament fabrication (FFF), such as five-axis printing, patching existing parts, and certain hybrid manufacturing processes, involve printing atop a previously manufactured polymer substrate. The success of these technologies depends upon the bond strength between the substrate and the newly added geometry. ANOVA and response surface methods were used to determine the effect of three process parameters on bond tensile strength: surface roughness, layer thickness, and raster angle. Experimental results indicate that the process–property relationships are not identical to those found in single, continuous FFF operations, and that the physical bonding mechanisms may also be different. Bond strength was found to be highly sensitive to surface roughness and layer thickness, and distinct optimal parameter settings exist. These results represent a first step toward understanding bond strength in such circumstances, allowing manufacturers to intelligently select process parameters for the production of both the substrate and the secondary geometry.

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