Multiresponse Optimization of Fused Deposition Modeling Process Using Utility-Based Taguchi Approach

2018 ◽  
Vol 17 (04) ◽  
pp. 551-568 ◽  
Author(s):  
Saurabh Verma ◽  
Vedansh Chaturvedi
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Optimum Process ◽  
Utility Concept ◽  
Fused Deposition ◽  
Multiresponse Optimization ◽  
Raster Angle ◽  
Deposition Modeling ◽  
Part Orientation

Rapid Prototyping (RP) technology has become the powerful tool for product development in almost every branch of engineering. Many new and upcoming processes offer means for the fast creation of models with steadily increasing accuracy, built speed, other model properties and economic advantages. Fused Deposition Modeling (FDM) is the most famous and commercially available RP system. This paper presents the application of Utility concept with Taguchi method for multiresponse optimization of the FDM process. Stratatys Fortus 400[Formula: see text]mc FDM setup is used to conduct experiments as per Taguchi’s L9 orthogonal array. FDM parameters: Layer thickness, part orientation and raster angle were optimized based on multiple responses, i.e. tensile, flexural, impact and compressive strength. The optimum process parameters are calculated using utility concept. The Analysis of variance (ANOVA) is applied to find out the most significant factor. It has been found that layer thickness is the most significant factor, followed by part orientation and raster angle. The confirmation tests with optimal levels of process parameters are conducted to illustrate the efficacy of the proposed method. It is found that optimum combination of process parameters gives the highest utility value, which indicates that multiresponses of the FDM process can be improved through this approach.

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.

scholarly journals Optimizing process parameters to improve the compressive strength of FDM products (Fused Deposition Modeling)

2017 ◽  
Vol 20 (K5) ◽  
pp. 37-43
Author(s):  
Nghi Huu Huynh ◽  
Ton Minh Tran ◽  
Tho Huu Nguyen ◽  
Ha Thi Thu Thai
Keyword(s):  
Compressive Strength ◽  
3D Printing ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Industrial Revolution ◽  
Optimum Process ◽  
Modeling Technology ◽  
Fused Deposition ◽  
Raster Angle ◽  
Deposition Modeling

Nowadays, 3D Printing Technology, also known as AM - Additive Manufacturing plays an important role in the 4.0 industrial revolution. In 3D printing technologies, FDM (Fused Deposition Modeling) technology is the most popular technology. In general, the quality of AM products and FDM depend on the process parameters. The article addressed the issue of optimizing process parameters to improve the compressive strength of the product. The parameters are considered as the fill pattern, fill density, number of contours, layer thickness and raster angle. The experimental design based on the Taguchi method is employed to identify the optimum process parameters. In addition, ANOVA is also utilized to evaluate the effect of each parameter on the compressive strength of the product.

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.

scholarly journals Preparation of Hydrophobic Surface on PLA and ABS by Fused Deposition Modeling

Polymers ◽  
2020 ◽  
Vol 12 (7) ◽  
pp. 1539 ◽  
Author(s):  
Huadong Yang ◽  
Fengchao Ji ◽  
Zhen Li ◽  
Shuai Tao
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Hydrophobic Coatings ◽  
Fused Deposition ◽  
Filling Method ◽  
Deposition Modeling ◽  
Experiment Analysis ◽  
Printing Speed

In the fields of agriculture, medical treatment, food, and packaging, polymers are required to have the characteristics of self-cleaning, anti-icing, and anti-corrosion. The traditional preparation method of hydrophobic coatings is costly and the process is complex, which has special requirements on the surface of the part. In this study, fused deposition modeling (FDM) 3D printing technology with design and processing flexibility was applied to the preparation of hydrophobic coatings on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts, and the relationship between the printing process parameters and the surface roughness and wettability of the printed test parts was discussed. The experimental results show that the layer thickness and filling method have a significant effect on the surface roughness of the 3D-printed parts, while the printing speed has no effect on the surface roughness. The orthogonal experiment analysis method was used to perform the wettability experiment analysis, and the optimal preparation process parameters were found to be a layer thickness of 0.25 mm, the Grid filling method, and a printing speed of 150 mm/s.

Improvement in Tensile Strength of FDM Built Parts by Parametric Control

2014 ◽  
Vol 592-594 ◽  
pp. 1075-1079 ◽  
Author(s):  
Swayam Bikash Mishra ◽  
Siba Sankar Mahapatra
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Optimal Parameter ◽  
Layer By Layer ◽  
3D Objects ◽  
Fused Deposition ◽  
Solid Models ◽  
Raster Angle ◽  
Deposition Modeling

Fused Deposition Modeling (FDM) is one of the efficient rapid prototyping (RP) technologies that forms 3D objects by adding material layer by layer from CAD generated solid models. However, the FDM built part is hardly anisotropic in nature due to layer-by-layer build mechanism. Literature suggests that mechanical property, especially tensile strength, of FDM built part is severely affected by process parameters. Among all the parameters, contour number happens to be an important parameter because it reduces stress concentration resulting in avoidance of premature breakdown. Therefore, in this work contour number along with five important process parameters such as layer thickness, raster width, part orientation, raster angle and air gap are considered and their effect on tensile strength of FDM built parts is studied. Experiments are conducted using Face Centred Central Composite Design (FCCCD) in order to reduce the experimental runs. An optimal parameter setting has been suggested for the maximisation of tensile strength of the FDM built parts.

Linear model analysis of fused deposition modeling process parameters for obtaining the maximum tensile strength in acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) materials

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Debashis Mishra ◽  
Anil Kumar Das
Keyword(s):  
Tensile Strength ◽  
Carbon Fiber ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Thermoplastic Material ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Speed

PurposeThe purpose of the experimental investigation was to optimize the process parameters of the fused deposition modeling (FDM) technique. The optimization of the process was performed to identify the relationship between the chosen factors and the tensile strength of acrylonitrile butadiene styrene (ABS) and carbon fiber polylactic acid (PLA) thermoplastic material, FDM printed specimens. The relationship was demonstrated by using the linear experimental model analysis, and a prediction expression was established. The developed prediction expression can be used for the prediction of tensile strength of selected thermoplastic materials at a 95% confidence level.Design/methodology/approachThe Taguchi L9 experimental methodology was used to plan the total number of experiments to be performed. The process parameters were chosen as three at three working levels. The working range of chosen factors was the printing speed (60, 80 and 100mm/min), 40%, 60% and 80% as the infill density and 0.1mm, 0.2mm and 0.3mm as the layer thickness. The fused deposition modeling process parameters were optimized to get the maximum tensile strength in FDM printed ABS and carbon fiber PLA thermoplastic material specimens.FindingsThe optimum condition was achieved by the process optimization, and the desired results were obtained. The maximum desirability was achieved as 0.98 (98%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.3mm. The strength of the ABS specimen was predicted to be 23.83MPa. The observed strength value was 23.66MPa. The maximum desirability was obtained as 1 (100%) for the factors, printing speed 100mm/min, infill density 60mm and layer thickness 0.2mm. The strength of the carbon fiber PLA specimen was predicted to be 26.23MPa, and the obtained value was 26.49MPa.Research limitations/implicationsThe research shows the useful process parameters and their suitable working conditions to print the tensile specimens of the ABS and carbon fiber PLA thermoplastics by using the fused deposition modeling technique. The process was optimized to identify the most influential factor, and the desired optimum condition was achieved at which the maximum tensile strength was reported. The produced prediction expression can be used to predict the tensile strength of ABS and carbon fiber PLA filaments.Practical implicationsThe results obtained from the experimental investigation are useful to get an insight into the FDM process and working limits to print the parts by using the ABS and carbon fiber PLA material for various industrial and structural applications.Social implicationsThe results will be useful in choosing the suitable thermoplastic filament for the various prototyping and structural applications. The products that require freedom in design and are difficult to produce by most of the conventional techniques can be produced at low cost and in less time by the fused deposition modeling technique.Originality/valueThe process optimization shows the practical exposures to state an optimum working condition to print the ABS and carbon fiber PLA tensile specimens by using the FDM technique. The carbon fiber PLA shows better strength than ABS thermoplastic material.

Optimization of fused deposition modeling process parameters using the Taguchi method to improve the tensile properties of 3D-printed polyether ether ketone

2021 ◽  
pp. 146442072110175
Author(s):  
Timoumi Mohamed ◽  
Najoua Barhoumi ◽  
Khalid Lamnawar ◽  
Abderrahim Maazouz ◽  
Amna Znaidi
Keyword(s):  
Tensile Properties ◽  
Young’S Modulus ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Young's Modulus ◽  
Fused Deposition ◽  
Polyether Ether Ketone ◽  
Deposition Modeling ◽  
Ether Ketone

The interesting mechanical properties of polyether ether ketone give the material a place among the foremost competitors when it comes to replacing metal. Fused deposition modeling has been recognized as an alternative method to process polyether ether ketone parts. In this study, the effect of different process parameters such as nozzle, bed, and radiant temperatures as well as printing speed and layer thickness on the tensile properties of three-dimensional printed polyether ether ketone was investigated. The optimization of the tensile properties of PEEK were studied by performing a reduced number of experiments, using the experimental design method based on the Taguchi approach which limits the number of experiments to 8 instead of 32. Results showed that a decent Young’s modulus was found by setting the nozzle temperature, print speed, and bed temperatures to their high levels and by setting the layer thickness and radiant temperature to their low level. Using these parameters, a Young’s modulus of 3.5 GPa was obtained, which represents 87.5% of the value indicated in the technical sheet. With these settings, we also found a tensile strength of 45.5 MPa, which corresponds to 46.4% of the value given by the studied polyether ether ketone material. A scanning electron microscopic investigation of the porosity and interlayer adhesion, confirmed that a higher bed temperature also tended to promote adhesion between layers.

scholarly journals OPTIMIZATION OF FUSED DEPOSITION MODELING PROCESS PARAMETERS FOR MATERIAL CONSUMPTION AND MANUFACTURING TIME

2021 ◽  
Author(s):  
Shrikrishna Pawar ◽  
◽  
Sarfraz Ali Quadri ◽  
Dr. Dhananjay Dolas ◽  
◽  
...  
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Material Consumption ◽  
Time Layer ◽  
Build Orientation ◽  
Fused Deposition ◽  
Modeling Process ◽  
Deposition Modeling ◽  
Manufacturing Time

This paper aims to explore the effect of layer thickness, infill density and build orientation on the material consumption and manufacturing time of specimens printed by the fused deposition modeling process. Specimens in accordance with ASTM Standards were printed by varying the process parameters such as layer thickness, infill density and build orientation. Time required to manufacture the part and amount of material consumed during the process are recorded. Increase in infill density results into increase in material consumption and manufacturing time. Layer thickness and build orientation also impacts manufacturing time and material consumption respectively. With increased application of FDM process, determining the process parameter to decrease the material consumption and manufacturing time shall help the FDM practitioners globally. Present work elucidates the optimization of FDM process parameters to achieve minimum material consumption and manufacturing time.

Effect of process parameters of fused deposition modeling on mechanical properties of poly-ether-ether-ketone and carbon fiber/poly-ether-ether-ketone

2022 ◽  
pp. 095400832110673
Author(s):  
Pei Wang ◽  
Aigang Pan ◽  
Liu Xia ◽  
Yitao Cao ◽  
Hongjie Zhang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Ether Ether Ketone ◽  
Poly Ether Ether Ketone ◽  
Raster Angle ◽  
Deposition Modeling ◽  
Ether Ketone ◽  
Nozzle Temperature

As a rapidly developing additive manufacturing technology, fused deposition modeling (FDM) has become widespread in many industry fields. It can fabricate complicated geometries using filament of thermoplastic materials such as PP, polylactic acid, acrylonitrile butadiene styrene, etc. However, poor mechanical properties of raw materials limit their application. Poly-ether-ether-ketone is a type of special engineering plastic with high performance, which could be further reinforced by adding carbon fibers (CFs). During FDM process, the mechanical properties of printed parts are largely subject to careful selection of process parameters. To improve the mechanical properties of PEEK and CF/PEEK 3D-printed parts, the effects of various process parameters including building orientation, raster angle, nozzle temperature, platform temperature, ambient temperature, printing speed, layer thickness, infill density, and number of printed parts on mechanical properties were investigated. The tensile fracture interfaces of printed parts were observed by scanning electron microscope (SEM) to explain the influence mechanism of process parameters. In the single factor experiments, flat and on-edge specimens show the best tensile and flexural strength, respectively; the specimens with raster angle ±45° and 0° show the best tensile and flexural strength, respectively. When the nozzle temperature at 500°C, platform temperature at 200°C, ambient temperature at 150°C, printing speed is 20 mm/s, layer thickness is 0.2 mm, and infill density is 100%, the printed parts exhibit the best mechanical properties.

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