Modeling and Experimental Validation of Part-Level Thermal Profile in Fused Filament Fabrication

2019 ◽  
Author(s):  
Mriganka Roy ◽  
Reza Yavari ◽  
Chi Zhou ◽  
Olga Wodo ◽  
Prahalad Rao
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Feed Rate ◽  
Experimental Validation ◽  
Acrylonitrile Butadiene Styrene ◽  
Temperature Profiles ◽  
Maximum Absolute Error ◽  
Shape Distortion ◽  
Fused Filament Fabrication ◽  
Thermal Profile

Abstract Part design and process parameters directly influence the spatiotemporal distribution of temperature and associated heat transfer in parts made using additive manufacturing (AM) processes. The temporal evolution of temperature in AM parts is termed herein as thermal profile or thermal history. The thermal profile of the part, in turn, governs the formation of defects, such as porosity and shape distortion. Accordingly, the goal of this work is to understand the effect of the process parameters and the geometry on the thermal profile in AM parts. As a step towards this goal, the objectives of this work are two-fold: (1) to develop and apply a finite element-based framework that captures the transient thermal phenomena in the fused filament fabrication (FFF) additive manufacturing of acrylonitrile butadiene styrene (ABS) parts, and (2) validate the model-derived thermal profiles with experimental in-process measurements of the temperature trends obtained under different feed rate settings (viz., the translation velocity, also called scan speed or deposition speed, of the extruder on the FFF machine). In the specific context of FFF, this foray is the critical first-step towards understanding how and why the thermal profile directly affects the degree of bonding between adjacent roads (linear track of deposited material), which in turn determines the strength of the part, as well as, propensity to form defects, such as delamination. From the experimental validation perspective, we instrumented a Hyrel Hydra FFF machine with three non-contact infrared temperature sensors (thermocouples) located near the nozzle (extruder) of the machine. These sensors measure the surface temperature of a road as it is deposited. Test parts are printed under three different settings of feed rate, and subsequently, the temperature profiles acquired from the infrared thermocouples are juxtaposed against the model-derived temperature profiles. Comparison of the experimental and model-derived thermal profiles confirms a high-degree of correlation therein, with maximum absolute error less than 10%. This work thus presents one of the first efforts in validation of thermal profiles in FFF via in-process sensing. In our future work, we will focus on predicting defects, such as delamination and inter-road porosity based on the thermal profile.

scholarly journals Prediction and Experimental Validation of Part Thermal History in the Fused Filament Fabrication Additive Manufacturing Process

2019 ◽  
Vol 141 (12) ◽  
Author(s):  
Mriganka Roy ◽  
Reza Yavari ◽  
Chi Zhou ◽  
Olga Wodo ◽  
Prahalada Rao
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Thermal History ◽  
Experimental Validation ◽  
Mean Squared Error ◽  
Percentage Error ◽  
Temperature Profiles ◽  
Shape Distortion ◽  
Fused Filament Fabrication ◽  
Thermal Profile

Abstract Part design and process parameters directly influence the instantaneous spatiotemporal distribution of temperature in parts made using additive manufacturing (AM) processes. The temporal evolution of temperature in AM parts is termed herein as the thermal profile or thermal history. The thermal profile of the part, in turn, governs the formation of defects, such as porosity and shape distortion. Accordingly, the goal of this work is to understand the effect of the process parameters and the geometry on the thermal profile in AM parts. As a step toward this goal, the objectives of this work are two-fold. First, to develop and apply a finite element-based framework that captures the transient thermal phenomena in the fused filament fabrication (FFF) additive manufacturing of acrylonitrile butadiene styrene (ABS) parts. Second, validate the model-derived thermal profiles with experimental in-process measurements of the temperature trends obtained under different material deposition speeds. In the specific context of FFF, this foray is the critical first-step toward understanding how and why the thermal profile directly affects the degree of bonding between adjacent roads (linear track of deposited material), which in turn determines the strength of the part, as well as, propensity to form defects, such as delamination. From the experimental validation perspective, we instrumented a Hyrel Hydra FFF machine with three non-contact infrared temperature sensors (thermocouples) located near the nozzle (extruder) of the machine. These sensors measure the surface temperature of a road as it is deposited. Test parts are printed under three different settings of feed rate, and subsequently, the temperature profiles acquired from the infrared thermocouples are juxtaposed against the model-derived temperature profiles. Comparison of the experimental and model-derived thermal profiles confirms a high degree of correlation therein, with a mean absolute percentage error less than 6% (root mean squared error <6 °C). This work thus presents one of the first efforts in validating thermal profiles in FFF via direct in situ measurement of the temperature. In our future work, we will focus on predicting defects, such as delamination and inter-road porosity based on the thermal profile.

Impact of quasi-isotropic raster layup on the mechanical behaviour of fused filament fabrication parts

2021 ◽  
pp. 095400832110419
Author(s):  
Lovin K John ◽  
Ramu Murugan ◽  
Sarat Singamneni
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Mechanical Strength ◽  
Process Parameters ◽  
Mechanical Behaviour ◽  
Fused Filament Fabrication ◽  
Anisotropic Behaviour ◽  
Oriented Samples ◽  
Weak Interlayer ◽  
Special Concern

The development of fused filament fabrication has extended the range of application of additive manufacturing in various areas of research. However, the mechanical strength of the fused filament fabrication–printed parts were considerably lower than that of parts fabricated by other conventional methods, owing to the observed anisotropic behaviour and formation of voids by weak interlayer diffusion. Intense studies on the effect of design and process parameters of the printed parts on the mechanical properties have been done, whereas studies on the effect of build orientations and raster patterns needs special concern. The main aim of this work is to fabricate parts printed using quasi-isotropic laminate arrangement of rasters, achieved by a raster layup of [45/0/−45/90]s, and to compare their mechanical properties with those of the commonly used 0°/90° (cross) and 45°/−45° (crisscross) raster oriented parts. The quasi-isotropic–oriented samples were observed with improved mechanical behaviour in tensile, compressive, flexural and impact tests compared to the commonly employed raster orientations.

scholarly journals Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes

2020 ◽  
Vol 12 (9) ◽  
pp. 3568 ◽  
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Athena Maniadi ◽  
Emmanuel Koudoumas ◽  
Achilles Vairis ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Behavior ◽  
Mechanical Response ◽  
Positive Impact ◽  
Research Work ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Simulation ◽  
Recycling Rate ◽  
Fused Filament Fabrication ◽  
Butadiene Styrene

Sustainability in additive manufacturing refers mainly to the recycling rate of polymers and composites used in fused filament fabrication (FFF), which nowadays are rapidly increasing in volume and value. Recycling of such materials is mostly a thermomechanical process that modifies their overall mechanical behavior. The present research work focuses on the acrylonitrile-butadiene-styrene (ABS) polymer, which is the second most popular material used in FFF-3D printing. In order to investigate the effect of the recycling courses on the mechanical response of the ABS polymer, an experimental simulation of the recycling process that isolates the thermomechanical treatment from other parameters (i.e., contamination, ageing, etc.) has been performed. To quantify the effect of repeated recycling processes on the mechanic response of the ABS polymer, a wide variety of mechanical tests were conducted on FFF-printed specimens. Regarding this, standard tensile, compression, flexion, impact and micro-hardness tests were performed per recycle repetition. The findings prove that the mechanical response of the recycled ABS polymer is generally improved over the recycling repetitions for a certain number of repetitions. An optimum overall mechanical behavior is found between the third and the fifth repetition, indicating a significant positive impact of the ABS polymer recycling, besides the environmental one.

scholarly journals Comparative study of the flexural properties of ABS, PLA and a PLA–wood composite manufactured through fused filament fabrication

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
J.A. Travieso-Rodriguez ◽  
R. Jerez-Mesa ◽  
Jordi Llumà ◽  
Giovanni Gomez-Gras ◽  
Oriol Casadesus
Keyword(s):  
Additive Manufacturing ◽  
Acrylonitrile Butadiene Styrene ◽  
Nozzle Diameter ◽  
Bending Test ◽  
Mechanical Resistance ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Layer Height ◽  
Maximum Deformation ◽  
Materials Used

Purpose The aim of this paper is to analyze the mechanical properties of acrylonitrile-butadiene-styrene (ABS) parts manufactured through fused filament fabrication and compare these results to analogous ones obtained on polylactic acid (PLA) and PLA–wood specimens to contribute for a wider understanding of the different materials used for additive manufacturing. Design/methodology/approach With that aim, an experimental based on an L27 Taguchi array was used to combine the specific parameters taken into account in the study, namely, layer height, nozzle diameter, infill density, orientation and printing velocity. All samples were subjected to a four-point bending test performed according to the ASTM D6272 standard. Findings Young’s modulus, elastic limit, maximum stress and maximum deformation of every sample were computed and subjected to an analysis of variance. Results prove that layer height and nozzle diameter are the most significant factors that affect the mechanical resistance in pieces generated through additive manufacturing and subjected to bending loads, regardless of the material. Practical implications The best results were obtained by combining a layer height of 0.1 mm and a nozzle diameter of 0.6 mm. The comparison of materials evidenced that PLA and its composite version reinforced with wood particles present more rigidity than ABS, whereas the latter can experience further deflection before break. Originality/value This study is of interest for manufacturers that want to decide which is the best material to be applied for their application, as it derives in a practical technical recommendation of the best parameters that should be selected to treat the material during the fused filament fabrication process.

Impact of Print Parameters on Pressure Drop in Turbulent Flow Through 3-D Printed Pipes

2020 ◽  
Author(s):  
Thomas G. Shepard ◽  
John Wentz ◽  
Tucker Bender ◽  
Derek Olmschenk ◽  
Alex Gutenberg
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Flow Characteristics ◽  
Internal Flow ◽  
Acrylonitrile Butadiene Styrene ◽  
Industrial Applications ◽  
Relative Pressure ◽  
Fused Filament Fabrication ◽  
Pressure Drops ◽  
Flow Through

Abstract Flow conduits made via additive manufacturing, commonly referred to as 3-D printing, are of increasing interest for a variety of industrial applications due to the ability to create unique and conformal flow paths that would not be possible with other fabrication techniques. Fused filament fabrication (FFF) is an additive manufacturing technique that is seeing new interest in the creation of internal flow channels with its ability to print high-temperature polymers and soluble supports. Printing parameter choices in the FFF printing process result in surfaces that can have significant profile differences that may significantly impact the flow characteristics within the conduits. In this study, two print parameters were experimentally studied for turbulent water flow through circular pipes created by fused filament fabrication out of acrylonitrile butadiene styrene (ABS). The print layer orientation relative to the flow was investigated for printing layers parallel, perpendicular, and at 45 degrees from the flow axis. Layer thickness were varied from 0.254 mm to 0.330 mm and all channels were created using soluble support structures. Pressure drops were measured for fully developed flow through pipes with an inside diameter of 5 mm and Reynolds numbers up to 62,000. Results are presented in terms of relative pressure drops as well as the wall surface roughness that would lead to such impacts. These flow-determined grain surface roughnesses are then compared against measurements of print surface roughness.

A Sensitivity Analysis Study on the Material Properties and Process Parameters for Selective Laser Melting of Inconel 625

2015 ◽  
Author(s):  
Luis E. Criales ◽  
Yiğit M. Arısoy ◽  
Tuğrul Özel
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Scanning Speed ◽  
Inconel 625 ◽  
Pool Data ◽  
Temperature Profiles ◽  
Laser Melting ◽  
Melt Pool ◽  
Laser Heat Source

A prediction of the 2-D temperature profile and melt pool geometry for Selective Laser Melting (SLM) of Inconel 625 metal powder with a numerically-based approach for solving the heat conduction-diffusion equation was established in this paper. A finite element method solution of the governing equation was developed. A review of the current efforts in numerical modeling for laser-based additive manufacturing is presented. Initially, two-dimensional (2-D) temperature profiles along the scanning (x-direction) and hatch direction (y-direction) are calculated for a moving laser heat source to understand the temperature rise due to heating during SLM. The effects of varying laser power, scanning speed and the powder material’s density are analyzed. Based on the predicted temperature distributions, melt pool geometry, i.e. the locations at which melting of the powder material occurs, is determined. The results are chiefly compared against the published literature on melt pool data. The main goal of this research is to develop a computational tool with which investigation of the importance of various laser, material, and process parameters on the built dimensional quality in laser-based additive manufacturing becomes not only possible but also practical and reproducible.

scholarly journals An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1649
Author(s):  
Jadwiga Pisula ◽  
Grzegorz Budzik ◽  
Paweł Turek ◽  
Mariusz Cieplak
Keyword(s):  
Additive Manufacturing ◽  
Operating Temperature ◽  
Coordinate Measuring Machine ◽  
Acrylonitrile Butadiene Styrene ◽  
Spur Gear ◽  
Gear Train ◽  
Tooth Surface ◽  
Fused Filament Fabrication ◽  
Measuring Machine ◽  
Manufacturing Techniques

This article focuses on wear tests of spur gears made with the use of additive manufacturing techniques from thermoplastic materials. The following additive manufacturing techniques were employed in this study: Melted and Extruded Modelling (FDM) and Fused Filament Fabrication (FFF). The study analysed gears made from ABS M-30 (Acrylonitrile Butadiene Styrene), ULTEM 9085 (PEI Polyetherimide) and PEEK (Polyetheretherketone), and the selection of these materials reflects their hierarchy in terms of economical application and strength parameters. A test rig designed by the authors was used to determine the fatigue life of polymer gears. Gear trains were tested under load in order to measure wear in polymer gears manufactured using FDM and FFF techniques. In order to understand the mechanism behind gear wear, further tests were performed on a P40 coordinate measuring machine (CMM) and a TalyScan 150 scanning instrument. The results of the gear tests made under load allow us to conclude that PEEK is resistant to wear and gear train operating temperature. Its initial topography undergoes slight changes in comparison to ABS M-30 and Ultem 9085. The biggest wear was reported for gears made from Ultem 9085. The hardness of the material decreased due to the loaded gear train’s operating temperature.

scholarly journals Influence of FFF process parameters and macrostructure homogeneity on PLA impact strength

Polimery ◽  
2021 ◽  
Vol 66 (9) ◽  
Author(s):  
Michał Bączkowski ◽  
Dawid Marciniak ◽  
Marek Bieliński
Keyword(s):  
Image Analysis ◽  
Additive Manufacturing ◽  
Impact Strength ◽  
Cross Section ◽  
Process Parameters ◽  
Optical Microscope ◽  
Process Variables ◽  
Fused Filament Fabrication ◽  
The Impact ◽  
Printing Parameters

The article presents studies of the additive manufacturing printing parameters influence onthe impact strength of PLA samples obtained by the fused filament fabrication (FFF) method. Two processvariables were taken into account in the research program: the height of the printed layer andthe printing temperature. An optical microscope was used to analyze the cross-section image (breakthrough)of the samples. The impact strength was determined at −40°C and 23°C. Selected geometricfeatures of the macrostructure (uniformity and thickness of individual layers, voids) determined on thebasis of the sample cross-section image analysis, enhanced the possibility of assessing the PLA impactstrength, depending on the adopted process variables and the temperature at which the experiment wascarried out.

scholarly journals Mechanical Strength Enhancement of 3D Printed Acrylonitrile Butadiene Styrene Polymer Components Using Neural Network Optimization Algorithm

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2250 ◽  
Author(s):  
Jasgurpreet Singh Chohan ◽  
Nitin Mittal ◽  
Raman Kumar ◽  
Sandeep Singh ◽  
Shubham Sharma ◽  
...  
Keyword(s):  
Neural Network ◽  
Mechanical Strength ◽  
Process Parameters ◽  
Low Cost ◽  
Impact Resistance ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Filament Fabrication ◽  
Neural Network Algorithm ◽  
Conventional Optimization ◽  
Butadiene Styrene

Fused filament fabrication (FFF), a portable, clean, low cost and flexible 3D printing technique, finds enormous applications in different sectors. The process has the ability to create ready to use tailor-made products within a few hours, and acrylonitrile butadiene styrene (ABS) is extensively employed in FFF due to high impact resistance and toughness. However, this technology has certain inherent process limitations, such as poor mechanical strength and surface finish, which can be improved by optimizing the process parameters. As the results of optimization studies primarily depend upon the efficiency of the mathematical tools, in this work, an attempt is made to investigate a novel optimization tool. This paper illustrates an optimization study of process parameters of FFF using neural network algorithm (NNA) based optimization to determine the tensile strength, flexural strength and impact strength of ABS parts. The study also compares the efficacy of NNA over conventional optimization tools. The advanced optimization successfully optimizes the process parameters of FFF and predicts maximum mechanical properties at the suggested parameter settings.

scholarly journals Multi-Objective Accelerated Process Optimization of Part Geometric Accuracy in Additive Manufacturing

2017 ◽  
Vol 139 (10) ◽  
Author(s):  
Amir M. Aboutaleb ◽  
Mark A. Tschopp ◽  
Prahalad K. Rao ◽  
Linkan Bian
Keyword(s):  
Experimental Data ◽  
Additive Manufacturing ◽  
Process Optimization ◽  
Process Parameters ◽  
Process Conditions ◽  
Optimization Approach ◽  
Geometric Accuracy ◽  
Multi Objective Optimization ◽  
Fused Filament Fabrication ◽  
Multi Objective

The goal of this work is to minimize geometric inaccuracies in parts printed using a fused filament fabrication (FFF) additive manufacturing (AM) process by optimizing the process parameters settings. This is a challenging proposition, because it is often difficult to satisfy the various specified geometric accuracy requirements by using the process parameters as the controlling factor. To overcome this challenge, the objective of this work is to develop and apply a multi-objective optimization approach to find the process parameters minimizing the overall geometric inaccuracies by balancing multiple requirements. The central hypothesis is that formulating such a multi-objective optimization problem as a series of simpler single-objective problems leads to optimal process conditions minimizing the overall geometric inaccuracy of AM parts with fewer trials compared to the traditional design of experiments (DOE) approaches. The proposed multi-objective accelerated process optimization (m-APO) method accelerates the optimization process by jointly solving the subproblems in a systematic manner. The m-APO maps and scales experimental data from previous subproblems to guide remaining subproblems that improve the solutions while reducing the number of experiments required. The presented hypothesis is tested with experimental data from the FFF AM process; the m-APO reduces the number of FFF trials by 20% for obtaining parts with the least geometric inaccuracies compared to full factorial DOE method. Furthermore, a series of studies conducted on synthetic responses affirmed the effectiveness of the proposed m-APO approach in more challenging scenarios evocative of large and nonconvex objective spaces. This outcome directly leads to minimization of expensive experimental trials in AM.

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