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 Suitability of Recycled PLA Filament Application in Fused Filament Fabrication Process

2021 ◽  
Vol 15 (4) ◽  
pp. 491-497
Author(s):  
Tomislav Breški ◽  
Lukas Hentschel ◽  
Damir Godec ◽  
Ivica Đuretek
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Polylactic Acid ◽  
Design Of Experiment ◽  
Experimental Approach ◽  
Manufacturing Processes ◽  
Support Structures ◽  
Fused Filament Fabrication ◽  
Layer Height ◽  
Printing Parameters

Fused filament fabrication (FFF) is currently one of the most popular additive manufacturing processes due to its simplicity and low running and material costs. Support structures, which are necessary for overhanging surfaces during production, in most cases need to be manually removed and as such, they become waste material. In this paper, experimental approach is utilised in order to assess suitability of recycling support structures into recycled filament for FFF process. Mechanical properties of standardized specimens made from recycled polylactic acid (PLA) filament as well as influence of layer height and infill density on those properties were investigated. Optimal printing parameters for recycled PLA filaments are determined with Design of Experiment methods (DOE).

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 The Impact of 3D Printing Process Parameters on the Dielectric Properties of High Permittivity Composites

Designs ◽  
2019 ◽  
Vol 3 (4) ◽  
pp. 50 ◽  
Author(s):  
Athanasios Goulas ◽  
Shiyu Zhang ◽  
Darren A. Cadman ◽  
Jan Järveläinen ◽  
Ville Mylläri ◽  
...  
Keyword(s):  
3D Printing ◽  
Process Parameters ◽  
Relative Permittivity ◽  
Main Process ◽  
Fused Filament Fabrication ◽  
Layer Height ◽  
Additive Manufacturing Technology ◽  
The Impact ◽  
Printing Speed ◽  
Hatch Spacing

Fused filament fabrication (FFF) is a well-known and greatly accessible additive manufacturing technology, that has found great use in the prototyping and manufacture of radiofrequency componentry, by using a range of composite thermoplastic materials that possess superior properties, when compared to standard materials for 3D printing. However, due to their nature and synthesis, they are often a great challenge to print successfully which in turn affects their microwave properties. Hence, determining the optimum printing strategy and settings is important to advance this area. The manufacturing study presented in this paper shows the impact of the main process parameters: printing speed, hatch spacing, layer height and material infill, during 3D printing on the relative permittivity (εr), and loss tangent (tanδ) of the resultant additively manufactured test samples. A combination of process parameters arising from this study, allowed successful 3D printing of test samples, that marked a relative permittivity of 9.06 ± 0.09 and dielectric loss of 0.032 ± 0.003.

Microstructure Analysis on GMAW Additive Manufacturing Parts Constrained by Electromagnetism

2014 ◽  
Vol 887-888 ◽  
pp. 1152-1155 ◽  
Author(s):  
Fan Jun Meng ◽  
De Ma Ba ◽  
Feng Liang Yin ◽  
Jun Du
Keyword(s):  
Additive Manufacturing ◽  
Cross Section ◽  
Optical Microscope ◽  
Electromagnetic Stirring ◽  
Primary Reason ◽  
Dendritic Crystal ◽  
Dc Magnetic Field ◽  
Stirring Effect ◽  
Part Structure ◽  
Heating Pattern

A GMAW additive manufacturing process is performed with H08Mn2Si wire to fabricate a cube forming part. A optical microscope was used to observe the cross section aspect of forming part and the structure mechanism has been analysed. The results demonstrate that the forming part structure presents a characteristic that macrostructure is uniform and microstructure changes circularly. The circularly heating pattern of GMAW surfacing forming results in circular microstructure change and preheating of formed bead to subsequent bead and postheating of subsequent bead to formed bead are primary reason. Electromagnetic stirring effect of longitudinal dc magnetic field to molten pool can break dendritic crystal and refine crystal grain, which is in favor of enhancing forming part performance.

scholarly journals Bonding between high-performance polymer processed by Fused Filament Fabrication and PEEK/carbon fiber laminate

2021 ◽  
Author(s):  
Isciane Caprais ◽  
Pierre Joyot ◽  
Emmanuel Duc ◽  
Simon Deseur
Keyword(s):  
Additive Manufacturing ◽  
Composite Structures ◽  
Composite Laminate ◽  
High Performance ◽  
Processing Conditions ◽  
Fused Filament Fabrication ◽  
Fiber Placement ◽  
High Performance Polymer ◽  
Automated Fiber Placement ◽  
The Impact

Automated fiber placement processes could be combined with additive manufacturing to produce more functionally complex composite structures with more flexibility. The challenge is to add functions or reinforcements to PEEK/carbon composite parts manufactured by automated fiber placement process, with additive manufacturing by fused filament fabrication. This consists of extruding a molten polymer through a nozzle to create a 3D part. Bonding between polymer filaments is a thermally driven phenomenon and determines the integrity and the final mechanical strength of the printed part. 3d-printing high performance polymers is still very challenging because they involve high thermal gradients during the process. The purpose of this work is to find a process window where the bonding strength is maximized between the composite laminate and the first layer of printed polymer, and inside the printed function as well. Experimental measurements of the temperature profiles at the interface between a composite substrate and 3d-printed PEI under different processing conditions were carried out. The interface was observed using microscopic sections. The methodology for studying the impact of printing parameters on the cohesion and adhesion of printed parts with a composite laminate is described. This work provides insights about the influence of processing conditions on the bond formation between high-performance polymer surfaces. It highlights the importance of controlling the thermal history of the materials all along the process.

scholarly journals ОСОБЛИВОСТІ ПЕРЕРОБКИ НАПОВНЕНИХ ПОЛІАМІДНИХ КОМПОЗИЦІЙ МЕТОДОМ ЛИТТЯ ПІД ТИСКОМ

2020 ◽  
Vol 140 (6) ◽  
pp. 71-80
Author(s):  
С. В. Пристинський ◽  
Ю. О. Будаш ◽  
В. І. Ступа ◽  
І. О. Пустовойт
Keyword(s):  
Comparative Analysis ◽  
Impact Strength ◽  
Injection Molding ◽  
Process Parameters ◽  
Polymer Composition ◽  
Injection Molding Process ◽  
Composition Material ◽  
Technological Parameters ◽  
Polyamide 6.6 ◽  
The Impact

Comparative analysis the main parameters of injection molding and the physic-mechanicals properties of polymer compositions based on polyamide 6.6. Samples we had obtained by injection molding method at injection molding machine ENGEL E-MAC 170/75. The process parameters had determined empirically to achieve certain quality criteria. Physics and mechanicals properties had evaluated by Sharpy impact strength. Statistical data processing, construction of graphs and diagrams had done in MS Excel. During the researching, had done a comparative analysis of the main parameters of the injection molding process, physical and mechanical properties, such as impact strength of the samples obtained from the glass-filled polymer composition based on polyamide PA6.6-GFGB30 and the material without glass filler PA6.6. During the experiment and data, analysis had revealed an increase in the impact strength of samples by 43%, cast from polymeric composition material PA6.6-GFGB30 in comparison with PA6.6. At the same time the process parameters such as the temperature, which directly affects the energy resources consumption, did not receive statistically significant changes. Among the features of changes in process parameters, we can note an increase in switching pressure, a decrease in the dosing time, and others. In addition, the speed and linear values of the process have changed. For the first time had performed a detailed comparative analysis the main processing parameters by injection molding and the physic-mechanicals properties of polymer compositions based on polyamide 6.6. The results will allow a professional approach to the selection of polymer compositions and technological parameters the process of their processing by injection molding.

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.

Evaluation of the printing strategies design on the mechanical and tribological response of acrylonitrile styrene acrylate (ASA) additive manufacturing parts

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Juan Manuel Vázquez Martínez ◽  
David Piñero Vega ◽  
Jorge Salguero ◽  
Moises Batista
Keyword(s):  
Additive Manufacturing ◽  
Friction Coefficient ◽  
Wear Rate ◽  
Mechanical Behavior ◽  
Layer Thickness ◽  
Fused Filament Fabrication ◽  
Friction Forces ◽  
Content Type ◽  
Printing Parameters ◽  
Manufacturing Parameters

Purpose The evaluation of novel materials such as the acrylonitrile styrene acrylate (ASA) for tribological and mechanical conditions can provide a structural protection against the environmental and wear effects that results in the long-term integrity of the 3 D printed parts. Results of the experimental stage are intended to identify the influence of the printing conditions on the functional characteristics of ASA parts that results in variations of the friction coefficient, wear rate and tensile response. In addition, this study aims to highlight the relevance of printing parameters to avoid the use of chemical post-processing stages, increasing the performance and sustainability of the process. Design/methodology/approach In this research, an evaluation of the influence of printing parameters of layer thickness and temperature on the mechanical and tribological response have been carried out for ASA specimens manufactured by fused filament fabrication technology. For this purpose, a range of three different values of thickness of fused layer and three different printing temperatures were combined in the manufacturing process of tests samples. Mechanical behavior of the printed parts was evaluated by standard tensile tests, and friction forces were measured by pin-on-disk tribological tests against steel spheres. Findings Higher layer thickness of the printed parts shows lower resistance to tribological wear effects; in terms of friction coefficient and wear rate, this type of parts also presents lower tensile strength. It has been detected that mechanical and tribological behavior is highly related to the micro-geometrical characteristics of the printed surfaces, which can be controlled by the manufacturing parameters. Under this consideration, a reduction in the coefficient of friction near to 65% in the average value was obtained through the variation of the layer thickness of printed surfaces. Originality/value This research aims to fill a gap in the scientific literature about the use of specific additive manufacturing materials under dynamic contact. This paper is mainly focused on the influence of the manufacturing parameters on the tribological and mechanical behavior of a weather resistant polymer (ASA).

Data Driven Modeling and Optimization for Energy Efficiency in Additive Manufacturing Process With Geometric Accuracy Consideration

2018 ◽  
Author(s):  
Junfeng Ma ◽  
Wenmeng Tian ◽  
Morteza Alizadeh
Keyword(s):  
Energy Consumption ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Complex Geometry ◽  
Statistical Regression ◽  
Geometric Accuracy ◽  
Fused Deposition ◽  
Optimization Framework ◽  
Accuracy Measure ◽  
The Impact

Despite of its tremendous merits in producing parts with complex geometry and functionally graded materials, additive manufacturing (AM) is inherently an energy expensive process. Prior studies have shown that process parameters, such as printing resolution, printing speed, and printing temperature, are correlated to energy consumption per part. Moreover, part geometric accuracy is another major focus in AM research, and extensive studies have shown that the geometric accuracy of final parts is highly dependent on those process parameters as well. Though both energy consumption and part geometric accuracy heavily depend on the process parameters in AM processes, jointly considering the dual outputs in AM process is not fully investigated. The proposed study aims to obtain a quantitative understanding of the impact of these process parameters on AM energy consumption given part quality requirements, such as geometric accuracy. The study utilizes a MakerGear M2 fused deposition modeling (FDM) 3D printer to complete the designed experiments. By implementing experimental design and statistical regression analysis technologies, the study quantifies the correlation between AM process parameters and energy consumption as well as the final geometric accuracy measure. An optimization framework is proposed to minimize the energy consumption per part. The Kuhn-Tucker non-linear optimization algorithm is used to identify the optimal process parameters. This study is of significance to AM energy consumption in terms of jointly considering energy consumption and final part geometric accuracy in the optimization framework.

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