scholarly journals Comparison of different additive manufacturing patterns on the performance of rapid vacuum casting for mating parts via the Taguchi method

2020 ◽  
Vol 14 (1) ◽  
pp. 6417-6429 ◽  
Author(s):  
Nur Nabilah Mohd Mustafa ◽  
Aini Zuhra Abdul Kadir ◽  
N. H. Akhmal Ngadiman ◽  
A. Ma'aram ◽  
K. Zakaria
Keyword(s):  
Additive Manufacturing ◽  
Taguchi Method ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Vacuum Casting ◽  
Fused Deposition ◽  
Small Series ◽  
Master Pattern

Rapid vacuum casting has been proven to be a successful method in producing high-quality parts in small series. However, a challenge lies in the selection of proper Additive Manufacturing (AM) technologies for the development of a master pattern for the vacuum casting process. Each AM technologies differ from one another in terms of dimensional accuracy, surface finish, cost and lead times. The aim of this study is to investigate the performance of casting mating parts based on different additive manufacturing patterns for small batch. Three types of AM-based patterns: Fused Deposition Modeling (FDM), Stereolithography (SLA) and Multi-Jet Fusion (MJF) were compared. The Taguchi method, Signal to Noise ratio (S/N), Analysis of Variance (ANOVA) and T-test were conducted in determining the optimized parameters. From the findings, curing time is shown to be a significant parameter for dimensional accuracy and surface finish. Dimensional deviation varies in different directions of parts. For surface finish, there was only a slight change from the master pattern whereas the surface roughness of casting parts decreased within the range 0.23% to 2.85%. Tolerance grades for the selected dimensions of the parts were in the permissible range, based on ISO286-1:2010. When using distinct kinds of AM patterns to create replacement components, design tolerance is needed. It was suggested to select AM technology similar to that had been used for the original components.  Battery cover was selected as a case study to represent the mating application parts.

Investigations for Mechanical Properties of Hybrid Investment Casting: A Case Study

2014 ◽  
Vol 808 ◽  
pp. 89-95 ◽  
Author(s):  
Parlad Kumar ◽  
Rupinder Singh ◽  
I.P.S. Ahuja
Keyword(s):  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Manufacturing Processes ◽  
Biomedical Implant ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Investment Casting Process

Conventional investment casting is one of the old manufacturing processes. It involves expensive tooling for making sacrificial wax patterns to make ceramic moulds. However, with the emergence of rapid prototyping technologies, now it is possible to make and use plastic patterns instead of wax patterns along with some advantages. In this paper, plastic patterns have been prepared by using fused deposition modeling and used for investment casting process. A case study has been discussed to make a biomedical implant by the hybridization of fused deposition modeling with investment casting. Dimensional accuracy, surface finish and hardness of the casted biomedical implants have been tested and reported.

A review of melt extrusion additive manufacturing processes: II. Materials, dimensional accuracy, and surface roughness

2015 ◽  
Vol 21 (3) ◽  
pp. 250-261 ◽  
Author(s):  
Brian N. Turner ◽  
Scott A Gold
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Product Design ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Design Parameters ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Am Processes

Purpose – The purpose of this paper is to critically review the literature related to dimensional accuracy and surface roughness for fused deposition modeling and similar extrusion-based additive manufacturing or rapid prototyping processes. Design/methodology/approach – A systematic review of the literature was carried out by focusing on the relationship between process and product design parameters and the dimensional and surface properties of finished parts. Methods for evaluating these performance parameters are also reviewed. Findings – Fused deposition modeling® and related processes are the most widely used polymer rapid prototyping processes. For many applications, resolution, dimensional accuracy and surface roughness are among the most important properties in final parts. The influence of feedstock properties and system design on dimensional accuracy and resolution is reviewed. Thermal warping and shrinkage are often major sources of dimensional error in finished parts. This phenomenon is explored along with various approaches for evaluating dimensional accuracy. Product design parameters, in particular, slice height, strongly impact surface roughness. A geometric model for surface roughness is also reviewed. Originality/value – This represents the first review of extrusion AM processes focusing on dimensional accuracy and surface roughness. Understanding and improving relationships between materials, design parameters and the ultimate properties of finished parts will be key to improving extrusion AM processes and expanding their applications.

Parallel non-dominated sorting genetic algorithm-II for optimal part deposition orientation in additive manufacturing based on functional features

2017 ◽  
Vol 232 (19) ◽  
pp. 3384-3395 ◽  
Author(s):  
Renkai Huang ◽  
Ning Dai ◽  
Dawei Li ◽  
Xiaosheng Cheng ◽  
Hao Liu ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Industrial Grade ◽  
Build Time ◽  
Functional Features

Surface finish, especially the surface finish of functional features, and build time are two important concerns in additive manufacturing. A suitable part deposition orientation can enhance the surface quality of functional features and reduce the build time. This article proposes a novel method to obtain an optimum part deposition orientation for industrial-grade 3D printing based on fused deposition modeling process by considering two objective functions at a time, namely adaptive feature roughness (the weighted sum of all feature roughnesses) and build time. First, mesh segmentation and level classification of features are carried out. Then, models for evaluation of adaptive feature roughness and build time are established. Finally, a non-dominated sorting genetic algorithm-II based on Compute Unified Device Architecture is used to obtain the Pareto-optimal set. The feasible of the algorithm is evaluated on several examples. Results demonstrate that the proposed parallel algorithm obtains a limiting solution that enhances the surface quality of functional features significantly and reduces average running time by 94.8% compared with the traditional genetic algorithm.

scholarly journals PENENTUAN SETTING OPTIMAL MESIN 3D PRINTER BERBASIS FUSED DEPOSITION MODELING MENGGUNAKAN METODE TAGUCHI

2018 ◽  
Vol 4 (2) ◽  
Author(s):  
Anggit Prakasa ◽  
Setya Permana Sutisna ◽  
Anton Royanto Ahmad
Keyword(s):  
Experimental Design ◽  
Taguchi Method ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
High Accuracy ◽  
3D Printer ◽  
Fused Deposition ◽  
3D Printers ◽  
Optimal Setting ◽  
Deposition Modeling

<p>The 3D printers process is applied to create prototype components, but at the last 3D Printers are often applied as last products. So, high accuracy is required in this case. In this research will find the optimal<br />setting of the dimensional accuracy 3D printers based fused deposition modeling. The method used is<br />the Taguchi method, the reason for using this method its efficiency, this is because the Orthogonal<br />Array matrix requires less number of experiments than the classical experimental design. Analysis of<br />Variance is also needed in this method to see the factors that significantly influence the response<br />variable. The results of this study indicate that the factors that significantly influence is printspeed by<br />contributing 53.08%, flowrate contributes 16.4%, and temperature heater block contributes 3.85% and<br />optimal setting is temperature heater block 190º, print speed 60mm/s and flowrate 6.28 mm3/s. (A1,<br />C3 dan D2).</p>

Studies on Rapid Prototyping Pattern Using PLA Material and FDM Technique

2013 ◽  
Vol 465-466 ◽  
pp. 1070-1074 ◽  
Author(s):  
Mustaffa Ibrahim ◽  
M.N. Hafsa
Keyword(s):  
Surface Roughness ◽  
Rapid Prototyping ◽  
Fused Deposition Modeling ◽  
Hollow Structure ◽  
Dimensional Accuracy ◽  
Response Analysis ◽  
Fused Deposition ◽  
Pattern Structure ◽  
Master Pattern ◽  
Part Orientation

The development of Rapid Prototyping (RP) gave the consumer the ability to form prototype or a component of the prototype that can be directly used in assemblies and product testing for short or medium production with the least time consumed. The purpose of this paper is to study the dimensional accuracy and surface roughness for RP part as a master pattern for Investment Casting (IC) process. The material that been used is Polylactic acid (PLA) using a technique of Fused Deposition Modeling (FDM). The effects of internal pattern structure and part orientation during fabrication on the part master pattern can analyze from the response analysis. Results shows that PLA/FDM produced better accuracy and surface roughness when the part is fabricated with internal pattern structure compare to hollow structure. The internal pattern structures improved the quality of part and capable to supporting the design so that less warping or shrink. Part that built with 90o part orientation produced better accuracy and surface roughness compare to 0o part orientation.

Effect of raster inclinations and part positions on mechanical properties, surface roughness and manufacturing price of printed parts produced by fused deposition method

2020 ◽  
Vol 14 (4) ◽  
pp. 7416-7423
Author(s):  
Mohammed Yunus ◽  
Mohammad S. Alsoufi
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
3D Cad ◽  
Fused Deposition ◽  
Cad Models ◽  
Proper Values

Additive manufacturing (AM) technology has the ability to produce parts or products using data from 3D CAD models based on adding material. Fused deposition modeling (FDM) is among the most popular AM technologies wherein the plastic materials like acrylonitrile-butadiene-styrene filaments get added in the form of semi-molten plastic layers from bottom to top to produce the final product. Besides, the merits of using the FDM process, it faces challenges related to strength, dimensional accuracy, surface finish, and so on. The mechanical, tribological, and surface finish of functional parts is an essential consideration in FDM. In this work, the role of process parameters such as the part positions and raster inclinations involved in the manufacturing of parts by FDM has been evaluated experimentally to obtain the desired properties for reducing production time, the quantity of supporting material, and overall cost including maintenance costs. The study revealed that part position is a more significant parameter than the raster inclinations on the surface roughness and mechanical properties of the FDM parts. It also concludes with the proper values of part positions and raster inclinations for achieving optimal mechanical properties, roughness, and manufacturing costs to withstand operating loading conditions.

Evaluation of FDM Pattern with ABS and PLA Material

2013 ◽  
Vol 465-466 ◽  
pp. 55-59 ◽  
Author(s):  
M.N. Hafsa ◽  
Mustaffa Ibrahim ◽  
Md. Saidin Wahab ◽  
M.S. Zahid
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
Casting Process ◽  
Fused Deposition ◽  
Before And After ◽  
High Layer ◽  
Better Than

Selection of the most suitable Rapid Prototyping (RP) and manufacturing process for a specific part creation is a difficult task due to the development of RP processes and materials. Most current RP processes can build with more than one type of material. The paper presents the evaluation on Acrylonitrile Butadiene Styrene (ABS) and Polylactic acid (PLA) part produced from Fused Deposition Modeling (FDM) as a master pattern for Investment Casting (IC) process. The main purpose of this research is to evaluate the dimensional accuracy and surface roughness for hollow and solid part of FDM pattern for IC process with different layer thickness. The value were taken for both before and after the casting process. Results show that model fabricated with hollow internal pattern structure (ABS material) that produced by low layer thickness is better than other models in terms of its dimensional accuracy (-0.19666mm) and surface roughness (1.41μm). Even though the ABS built part performed better as the model, the PLA build part produces better overall casting result. Final part fabricated with solid pattern (PLA material) that produced by high layer thickness is better than other final parts which its dimensional accuracy (-0.12777mm) and surface roughness (3.07μm).

Process Parameter Optimization of Fused Deposition Modeling for Helical Surfaces Using Grey Relational Analysis

2016 ◽  
Vol 879 ◽  
pp. 861-866 ◽  
Author(s):  
T.G. Anusree ◽  
R.Nair Anjan ◽  
M. Sivadasan ◽  
T.D. John
Keyword(s):  
Tensile Strength ◽  
Parameter Optimization ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Process Parameter ◽  
Fused Deposition ◽  
Relational Analysis ◽  
Deposition Modeling ◽  
Grey Relational

Fused Deposition Modeling (FDM), a fast growing rapid prototyping technology, is a process for developing physical objects by adding fused layers of materials according to a three dimensional CAD geometry. FDM can be used to produce parts with complex geometries. Hence it gains distinct advantages in industries. One of the major drawbacks of FDM is the reduced part quality measured in terms of dimensional accuracy, surface finish and mechanical characteristics. The major share of research literature related to the field of FDM process parameter optimization focuses on flat and circular surfaces, while only a few studies are available on helical surfaces. This paper is based on a close study conducted to understand the effect of four parameters, namely, layer thickness, raster width, print speed and support material density on dimensional accuracy, tensile strength and surface finish of FDM processed helical surfaces. The experiments were designed by taking three levels of each process parameter selected. Optimum parameter level for improving dimensional accuracy, tensile strength and surface finish simultaneously were obtained by Grey Relational Analysis. The main effect plots were also analyzed.

Sign in / Sign up

Export Citation Format

Share Document