Experimental and statistical analysis of robotic 3D printing process parameters for continuous fiber reinforced composites

2021 ◽  
pp. 002199832199642
Author(s):  
Ahmet İpekçi ◽  
Bülent Ekici
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Flexural Strength ◽  
Uv Light ◽  
Continuous Fiber ◽  
Fiber Density ◽  
Printing Process ◽  
Manufacturing Methods ◽  
Structural Parts ◽  
Printing Speed

3D printing technology has gradually taken its place in many sectors. However, expected performance cannot be obtained from the structural parts with this method due to the raw material properties and constraints of Cartesian motion systems. This technology cannot replace structural parts produced by traditional manufacturing methods. In order to avoid these constraints, it is preferred to use continuous fiber reinforced polymer composites in many areas such as automotive and aerospace industries due to their low weight and high specific strength properties. These automated composite manufacturing methods currently have limited production of geometric shapes due to the need for additional molds and production as flat surfaces. To overcome all these constraints, fiberglass reinforced ultraviolet ray-curing polymer matrix composite material are selected for robotic 3 D printing process and various parameters are examined. Fiber-polymer combination and layer structure formation was examined. Scanning Electron Microscopy (SEM) images of sections of 3 D printed test samples were taken and fiber resin curing was examined. The nozzle diameter, printing speed, fiber density and Ultra Violet (UV) light intensity parameters, which will provide effective 3 D printing process, are optimized with the Taguchi method. Tensile strength, flexural strength and izod impact values are considered as result parameters for optimization. It was found that it would be appropriate for 3D printing with a 1.0 mm nozzle diameter, 600 tex fiber density, 4 UV light, 600 mm/min printing speed. With these 3D printing process parameters, approximately 125 MPa tensile strength and 450 MPa flexural strength can be obtained. With this study, support and contribution was provided to researchers, composite producers, tool manufacturer and literature who want to use and develop this 3D printing process.

scholarly journals Preliminary Study on Mechanical Properties of 3D Printed Multimaterials ABS/PC Parts: Effect of Printing Parameters

2021 ◽  
Vol 32 (2) ◽  
pp. 87-104
Author(s):  
Pui-Voon Yap ◽  
Ming-Yeng Chan ◽  
Seong-Chun Koay
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Flexural Strength ◽  
Young’S Modulus ◽  
Young's Modulus ◽  
Flexural Modulus ◽  
Nozzle Diameter ◽  
Fused Deposition ◽  
Printing Parameters ◽  
Printing Speed

This research work highlights the mechanical properties of multi-material by fused deposition modelling (FDM). The specimens for tensile and flexural test have been printed using polycarbonate (PC) material at different combinations of printing parameters. The effects of varied printing speed, infill density and nozzle diameter on the mechanical properties of specimens have been investigated. Multi-material specimens were fabricated with acrylonitrile butadiene styrene (ABS) as the base material and PC as the reinforced material at the optimum printing parameter combination. The specimens were then subjected to mechanical testing to observe their tensile strength, Young’s modulus, percentage elongation, flexural strength and flexural modulus. The outcome of replacing half of ABS with PC to create a multi-material part has been examined. As demonstrated by the results, the optimum combination of printing parameters is 60 mm/s printing speed, 15% infill density and 0.8 mm nozzle diameter. The combination of ABS and PC materials as reinforcing material has improved the tensile strength (by 38.46%), Young’s modulus (by 23.40%), flexural strength (by 23.90%) and flexural modulus (by 37.33%) while reducing the ductility by 14.31% as compared to pure ABS. The results have been supported by data and graphs of the analysed specimens.

scholarly journals New Materials for 3D-Printing Based on Polycaprolactone with Gum Rosin and Beeswax as Additives

Polymers ◽  
2020 ◽  
Vol 12 (2) ◽  
pp. 334 ◽  
Author(s):  
Cristina Pavon ◽  
Miguel Aldas ◽  
Juan López-Martínez ◽  
Santiago Ferrándiz
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Mechanical Characterization ◽  
Three Dimensional ◽  
New Materials ◽  
Elongation At Break ◽  
Printing Process ◽  
Gum Rosin ◽  
The Matrix ◽  
Natural Additives

In this work, different materials for three-dimensional (3D)-printing were studied, which based on polycaprolactone with two natural additives, gum rosin, and beeswax. During the 3D-printing process, the bed and extrusion temperatures of each formulation were established. After, the obtained materials were characterized by mechanical, thermal, and structural properties. The results showed that the formulation with containing polycaprolactone with a mixture of gum rosin and beeswax as additive behaved better during the 3D-printing process. Moreover, the miscibility and compatibility between the additives and the matrix were concluded through the thermal assessment. The mechanical characterization established that the addition of the mixture of gum rosin and beeswax provides greater tensile strength than those additives separately, facilitating 3D-printing. In contrast, the addition of beeswax increased the ductility of the material, which makes the 3D-printing processing difficult. Despite the fact that both natural additives had a plasticizing effect, the formulations containing gum rosin showed greater elongation at break. Finally, Fourier-Transform Infrared Spectroscopy assessment deduced that polycaprolactone interacts with the functional groups of the additives.

scholarly journals Binder jetting 3D printing process optimization for rapid casting of green parts with high tensile strength

China Foundry ◽  
2021 ◽  
Vol 18 (4) ◽  
pp. 335-343
Author(s):  
Zhao-fa Zhang ◽  
Li Wang ◽  
Lin-tao Zhang ◽  
Peng-fei Ma ◽  
Bing-heng Lu ◽  
...  
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Process Optimization ◽  
High Tensile Strength ◽  
Printing Process ◽  
Rapid Casting ◽  
Binder Jetting

scholarly journals Characterization of Recycled Polyethylene Terephthalate Powder for 3D Printing Feedstock

2019 ◽  
Vol 4 (2) ◽  
Author(s):  
Chukwunonso N Nwogu ◽  
Remy Uche ◽  
John O Igbokwe ◽  
Chukwunenye A Okoronkwo
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Flexural Strength ◽  
Bulk Density ◽  
Intrinsic Viscosity ◽  
Coefficient Of Friction ◽  
Flow Property ◽  
Grade One ◽  
Density Coefficient

This paper assessed the suitability of PET powder produced by crushing used plastic bottles as 3D printing feedstock. Characterization of the powder was done through determining its flow property, coefficient of friction, bulk density, flexural and tensile strengths and compared with those of ABS, PLA, PVA, Nylon and HDPE which are used conventionally 3D printing of plastic parts. Two grades of PET bottles were used in this study: grade one which is designated PET1 with intrinsic viscosity values ranging from 0.78-0.80 (used for water bottles) and grade two which is designated PET2 with intrinsic viscosity values ranging from 0.80-0.85 (used for carbonated drinks bottles). The results of the tests performed showed that PET1 has bulk density, coefficient of friction, flexural strength and tensile strength values of 0.16 g/m3, 0.43, 82.1 MPa and 63.4 MPa respectively while PET2 has bulk density, coefficient of friction, flexural strength and tensile strength values of 0.15 g/m3, 0.22, 82.7 MPa and 57.8 MPa respectively. The Experimental results show that both PET1 and PET2 have very good flow property, and are suitable for 3D printing. This study solves two major problems: plastic waste management and availability of locally produced 3D printing feedstock, which is currently the greatest challenge of 3D printing in Nigeria. Keywords— 3D printing feedstock, Characterization, Intrinsic viscosity, PET powder.

scholarly journals Optimasi Parameter Proses 3D Printing Terhadap Kuat Tarik Material Filamen PLA + Menggunakan Metode Taguchi

2021 ◽  
Vol 3 (1) ◽  
pp. 39-45
Author(s):  
Wahyudi Hafizi Pratama ◽  
Hasdiansah - ◽  
Husman -
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Layer Thickness ◽  
Tensile Testing ◽  
Fused Deposition Modeling ◽  
Production Costs ◽  
Fused Deposition ◽  
Cooling Speed ◽  
Printing Machine ◽  
Printing Speed

FDM (Fused Deposition Modeling) is one of the methods often usen by researchers in 3D printing technology which is used to print filaments products as a materials, due to the easy technique for 3D printing with relatively low production costs. One of the materials that can be processed in a 3D printing machine ia PLA+. Research in tensile testing has been  done on PLA and ABS filaments. Meanwhile, tensile testing using PLA+ filaments is still rarely done. From these problems, research is needed to get the optimal process parameters on the 3D printing machine to get the highest tensile strenght value using PLA+ filaments. This research uses the taguchi method, carried out on a PRUSA area model FDM 3D Printing machine with dimensions of 300mm x 300mm x 350mm using a nozzle size of 0.4mm. The material used is PLA + Esun filament with a diameter of 1.75 mm with a variety of printing speed parameters (30 mm/s, 35 mm/s, 40 mm/s, 45 mm/s, 50 mm/s), nozzle temperature (1950C, 2000C, 2050C, 2100C, 2150C), layer thickness (0.10mm, 0.15mm, 0.20mm, 0.25mm, 0.30mm), cooling speed (20%, 40%, 60%, 80%, 100%), orientation (00, 300, 450, 600,900) which will be determined in ideamaker 3.6.1 to produce 75 printed samples. This research aims to determine the optimal tensile strength value. From the research results there is an optimal tensile strength value, namely in experiment 10 with the parameter values of printing speed (35 mm/s), Nozzle Tenperature (2150C), Layer Thickness (0.10mm), Cooling speed (20%), and Orientation (450). with a tensile strength value of 48.1 MPa from 3 replications.

The Influence of an Infill Density, Percent on the Flexural Strength of the 3D

2020 ◽  
Vol 870 ◽  
pp. 73-80
Author(s):  
Nuha Hadi Jasim Al Hasan
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Polylactic Acid ◽  
Fused Deposition Modeling ◽  
Bending Test ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Deposition Modeling

3D printing innovation, as a quick prototyping, utilize plastic or metal as the crude material to print the genuine parts layer by layer. In this way, it is likewise called added substance producing procedure. Contrasted and conventional assembling innovation, 3D printing innovation has evident points of interest in assembling items with complex shapes and structures. Fused deposition modeling (FDM) is one of the most broadly utilized 3D printing advances. Fibers of thermoplastic materials, for example, polylactic acid is for the most part utilized as crude materials. The present examination will concentrate on the effect of the infill density, percent on the flexural strength of polylactic acid. Bending test was performed on different infill density, percent of specimens. According to ASTM D638.14 standards, samples for testing are made in different infill density, percent (20, 30, 40, 50 and 60 %) by using a polylactic acid in 3D machine printing and their tensile tested and the parameters include different fill density, layer high of 0.1 mm , 0.2mm and 0.3 have an effect on the mechanical characterized while the time of printing the sample would be increased with increasing of fill density%. The tensile strength of polylactic acid samples was found at different fill density and a layer thickness. According to test measuring results that the tensile strength, maximum 47.1,47.4, and 48 MPa at 30%,40%,and 50% fill density respectively and 0.1mm height layer and the tensile strength minimum at 60% and 70 % fill density and 0.1 mm height layer thickness. The higher strength results as higher layer thickness 0.3 mm as compared with 0.1 and 0.2 at 30%fill density.

3D printing for continuous fiber reinforced thermoplastic composites: mechanism and performance

2017 ◽  
Vol 23 (1) ◽  
pp. 209-215 ◽  
Author(s):  
Chuncheng Yang ◽  
Xiaoyong Tian ◽  
Tengfei Liu ◽  
Yi Cao ◽  
Dichen Li
Keyword(s):  
3D Printing ◽  
Acrylonitrile Butadiene Styrene ◽  
Industrial Applications ◽  
Mechanical Tests ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Printing Process ◽  
Content Type ◽  
The One

Purpose Continuous fiber reinforced thermoplastic composites (CFRTPCs) are becoming more significant in industrial applications but are limited by the high cost of molds, the manufacturing boundedness of complex constructions and the inability of special fiber alignment. The purpose of this paper is to put forward a novel three-dimensional (3D) printing process for CFRTPCs to realize the low-cost rapid fabrication of complicated composite components. Design/methodology/approach For this purpose, the mechanism of the proposed process, which consists of the thermoplastic polymer melting, the continuous fiber hot-dipping and the impregnated composites extruding, was investigated. A 3D printing equipment for CFRTPCs with a novel composite extrusion head was developed, and some composite samples have been fabricated for several mechanical tests. Moreover, the interface performance was clarified with scanning electron microscopy images. Findings The results showed that the flexural strength and the tensile strength of these 10 Wt.% continuous carbon fiber (CCF)/acrylonitrile-butadiene-styrene (ABS) specimens were improved to 127 and 147 MPa, respectively, far greater than the one of ABS parts and close to the one of CCF/ABS (injection molding) with the same fiber content. Moreover, these test results also exposed the very low interlaminar shear strength (only 2.81 MPa) and the inferior interface performance. These results were explained by the weak meso/micro/nano scale interfaces in the 3D printed composite parts. Originality/value The 3D printing process for CFRTPCs with its controlled capabilities for the orientation and distribution of fiber has great potential for manufacturing of load-bearing composite parts in the industrial circle.

scholarly journals Tensile Strength of Threaded Rods Made by 3D Printing of Polymeric Material

2022 ◽  
Vol 58 (4) ◽  
pp. 9-18
Author(s):  
Marius Ionut Ripanu ◽  
Andrei Marius Mihalache ◽  
Laurentiu Slatineanu ◽  
Marian Mares ◽  
Liviu Andrusca ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Tensile Strength ◽  
3D Printing ◽  
Polymeric Materials ◽  
Tensile Tests ◽  
Printing Process ◽  
Threaded Joint ◽  
Maximum Deformation ◽  
Tensile Forces ◽  
Printing Processes

The extension of 3D printing processes for parts made of polymeric materials highlighted the possibility of manufacturing threaded surfaces through such processes. In principle, the operation of a threaded joint involves tensile forces in the threaded rod. The dimensional characteristics of the threaded surface and some input factors in the 3D printing process can influence the tensile strength of threaded rods made of polymeric materials. An experimental research aimed at the tensile behavior of a threaded joint was designed, using a plastic screw and a special steel nut. A factorial experiment was designed and implemented to identify an empirical mathematical model capable of highlighting the influence of the dimensional characteristics of the threaded surface and some of the input factors in the 3D printing process on tensile strength. The test samples from polymeric materials were manufactured by 3D printing, then subjected to tensile tests. The mathematical processing of the experimental results allowed the determination of a mathematical model that allows the inclusion of the ordering of the factors taken into account in terms of the intensity of the influence that these factors exert on the tensile strength of the threaded rods. It was found that the diameter of the threaded rod exerts the strongest influence on the tensile strength of the threaded rod obtained by 3D printing, increasing the diameter of the threaded rod causing an increase in the maximum deformation of the rod. Increasing the thread pitch leads to a decrease in the maximum deformation of the threaded rod.

scholarly journals The use of statistical techniques to study the machine parameters affecting the properties of 3D printed cotton/polylactic acid fabrics

2020 ◽  
Vol 15 ◽  
pp. 155892502092853
Author(s):  
Nonsikelelo Sheron Mpofu ◽  
Josphat Igadwa Mwasiagi ◽  
Londiwe Cynthia Nkiwane ◽  
David Njuguna Githinji
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Polylactic Acid ◽  
Adhesion Force ◽  
Extrusion Temperature ◽  
Coefficient Of Determination ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
Before And After ◽  
Printing Speed

Textile materials have been combined with polymers using 3D printing technology, thus producing structures with novel properties. The aim of this study was to use statistical methods to determine the effect of 3D printing machine parameters on the mechanical properties of cotton fabrics combined with polylactic acid. Polylactic acid was printed on a cotton fabric using an Athena Fused Deposition Modelling 3D printer. The effect of extrusion temperature, printing speed, fill density and model height on adhesion force before and after washing was investigated. A study of the tensile strength was also undertaken using a central composite rotatable design and regression analysis. The experimental data were used to develop regression models to predict the properties of the cotton/ polylactic acid structures. The model for adhesion force before washing yielded a coefficient of determination (R2) value of 0.75 and an optimum adhesion force of 50.06 N/cm. The model for adhesion force had an R2 value of 0.84 and an optimum adhesion force of 42.91 N/cm and showed that adhesion force reduced after washing. Adhesion forces before and after washing were both positively correlated to extrusion temperature. However, they reduced with an increase in printing speed and model height. A positive correlation exists between tensile strength and temperature, while a negative correlation exists between tensile strength and printing speed and model height. From the results of this study, it was concluded that 3D printing parameters have an effect on the properties of the structures.

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