scholarly journals Taguchi S/N and TOPSIS Based Optimization of Fused Deposition Modelling and Vapor Finishing Process for Manufacturing of ABS Plastic Parts

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5176
Author(s):  
Jasgurpreet Singh Chohan ◽  
Raman Kumar ◽  
TH Bhatia Singh ◽  
Sandeep Singh ◽  
Shubham Sharma ◽  
...  
Keyword(s):  
Surface Roughness ◽  
New Product Development ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Orientation Angle ◽  
Fused Deposition Modelling ◽  
Strength Increase ◽  
Major Barrier ◽  
Practical Applications ◽  
Fused Deposition

Despite several additive manufacturing techniques are commercially available in market, Fused Deposition Modeling (FDM) is increasingly used by researchers and engineers for new product development. FDM is an established process with a plethora of advantages, but the visible surface roughness (SR), being an intrinsic limitation, is major barrier against utilization of fabricated parts for practical applications. In the present study, the chemical finishing method, using vapour of acetone mixed with heated air, is being used. The combined impact of orientation angle, finishing temperature and finishing time has been studied using Taguchi and ANOVA, whereas multi-criteria optimization is performed using the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). The surface finish was highly responsive to increase in temperature while orientation angle of 0° yielded maximum strength; increase in finishing time led to weight gain of FDM parts. As the temperature increases, the percentage change in surface roughness increases as higher temperature assists the melt down process. On the other hand, anisotropic behaviour plays a major role during tensile testing. The Signal-to-noise (S/N) ratio plots, and ANOVA results indicated that surface finish is directly proportionate to finishing time because a longer exposure results in complete layer reflowing and settlement.

scholarly journals Influence of Print Orientation on Surface Roughness in Fused Deposition Modeling (FDM) Processes

Materials ◽  
2019 ◽  
Vol 12 (23) ◽  
pp. 3834 ◽  
Author(s):  
Irene Buj-Corral ◽  
Alejandro Domínguez-Fernández ◽  
Ramón Durán-Llucià
Keyword(s):  
Surface Roughness ◽  
Fused Deposition Modeling ◽  
Orientation Angle ◽  
Geometrical Model ◽  
Fused Deposition Modelling ◽  
Maximum Height ◽  
Fused Deposition ◽  
Roughness Profile ◽  
Mean Width ◽  
Experimental Values

In the present paper, we address the influence of print orientation angle on surface roughness obtained in lateral walls in fused deposition modelling (FDM) processes. A geometrical model is defined that considers the shape of the filaments after deposition, in order to define a theoretical roughness profile, for a certain print orientation angle. Different angles were considered between 5° and 85°. Simulated arithmetical mean height of the roughness profile, Ra values, were calculated from the simulated profiles. The Ra simulated results were compared to the experimental results, which were carried out with cylindrical PLA (polylactic acid) samples. The simulated Ra values were similar to the experimental values, except for high angles above 80°, where experimental roughness decreased while simulated roughness was still high. Low print orientation angles show regular profiles with rounded peaks and sharp values. At a print orientation angle of 85°, the shape of the profile changes with respect to lower angles, showing a gap between adjacent peaks. At 90°, both simulated and experimental roughness values would be close to zero, because the measurement direction is parallel to the layer orientation. Other roughness parameters were also measured: maximum height of profile, Rz, kurtosis, Rku, skewness, Rsk, and mean width of the profile elements, Rsm. At high print orientation angles, Rz decreases, Rku shifts to positive, Rsk slightly increases, and Rsk decreases, showing the change in the shape of the roughness profiles.

Influence of Part Orientation on the Surface Roughness in the Process of Fused Deposition Modeling

2021 ◽  
Vol 896 ◽  
pp. 29-37
Author(s):  
Ján Milde ◽  
František Jurina ◽  
Jozef Peterka ◽  
Patrik Dobrovszký ◽  
Jakub Hrbál ◽  
...  
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Orientation Angle ◽  
Acrylonitrile Butadiene Styrene ◽  
Lower Surface ◽  
Geometrical Model ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Part Orientation

The article focused on the influence of part orientation on the surface roughness of cuboid parts during the process of fabricating by FDM technology. The components, in this case, is simple cuboid part with the dimensions 15 mm x 15mm x 30 mm. A geometrical model is defined that considers the shape of the material filaments after deposition, to define a theoretical roughness profile, for a certain print orientation angle. Five different print orientations in the X-axis of the cuboid part were set: 0°, 30°, 45°, 60°, and 90°. According to previous research in the field of FDM technology by the author, the internal structure (infill) was set at the value of 70%. The method of 3D printing was the Fused Deposition Modeling (FDM) and the material used in this research was thermoplastic ABS (Acrylonitrile butadiene styrene). For each setting, there were five specimens (twenty five prints in total). Prints were fabricated on a Zortrax M200 3D printer. After the 3D printing, the surface “A” was investigated by portable surface roughness tester Mitutoyo SJ-210. Surface roughness in the article is shown in the form of graphs (Fig.7). Results show increase in part roughness with increasing degree of part orientation. When the direction of applied layers on the measured surface was horizontal, significant improvement in surface roughness was observed. Findings in this paper can be taken into consideration when designing parts, as they can contribute in achieving lower surface roughness values.

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.

Effect of cold vapour treatment on geometric accuracy of fused deposition modelling parts

2017 ◽  
Vol 23 (6) ◽  
pp. 1226-1236 ◽  
Author(s):  
Ashu Garg ◽  
Anirban Bhattacharya ◽  
Ajay Batish
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Fused Deposition Modelling ◽  
Curved Surfaces ◽  
Geometric Accuracy ◽  
Content Type ◽  
Fused Deposition ◽  
Cold Vapour ◽  
Side Face ◽  
Functional Components

Purpose The purpose of this paper is to investigate the influence of low-cost chemical vapour treatment process on geometric accuracy and surface roughness of different curved and freeform surfaces of fused deposition modelling (FDM) specimens build at different part building orientations. Design/methodology/approach Parts with different primitive and curved surfaces are designed and modelled to build at three different part orientations along X orientation (vertical position resting on side face), Y orientation (horizontal position resting on base) and Z orientation (upright position). Later, the parts are post-processed by cold vapours of acetone. Geometric accuracy and surface roughness are measured both before and after the chemical treatment to investigate the change in geometric accuracy, surface roughness of FDM parts. Findings The results indicate that surface roughness is reduced immensely after cold vapour treatment with minimum variation in geometric accuracy of parts. Parts build vertically over its side face (X orientation) provides the overall better surface finish and geometric accuracy. Originality/value The present study provides an approach of post-built treatment for FDM parts and observes a significant improvement in surface finish of the components. The present approach of post-built treatment can be adopted to enhance the surface quality as well as to achieve desired geometric accuracy for different primitive, freeform/curved surfaces of FDM samples suitable for functional components as well as prototypes.

scholarly journals Quantitative analysis of 0% infill density surface profile of printed part fabricated by personal FDM 3D printer

2018 ◽  
Vol 7 (1) ◽  
pp. 44 ◽  
Author(s):  
Mohammad Alsoufi ◽  
Abdulrhman Elsayed
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Surface Profile ◽  
Cost Effective ◽  
Angle Measurement ◽  
3D Printer ◽  
Fused Deposition ◽  
3D Printed ◽  
Finishing Tool

Fused deposition modeling or FDM technology is an additive manufacturing (AM) technology commonly used for prototyping applications which suffer seriously from low levels of fluctuated surface finish quality, demanding some hand finishing tool for even the necessary levels of 3D printed parts. This paper, therefore, aims at giving close attention to the variation in the surface roughness profile between the inner and the outer faces of FDM 3D printed parts based on advanced polylactic acid (PLA+) thermoplastic filament material. The surface roughness is quantitatively analyzed using a contact-type test-rig with a 90° angle measurement on each face along with each zone and sub-zone. The obtained results revealed that the surface finish of the inner faces is rougher than those of the outer faces as regards nozzle temperature, nozzle diameter, infill density and layer height is 220°C, 0.5 mm, 0% and 0.3 mm, respectively. The personal FDM 3D printer is thus confirmed to be an excellent platform, flexible, straightforward and cost-effective. 

scholarly journals Parametric Effect on Surface Finish of Three-Dimensional Printed Object

2018 ◽  
Vol 3 (2) ◽  
pp. 98-104
Author(s):  
Muhammad Hasibul Hasan ◽  
Shugata Ahmed ◽  
Ron Voldman ◽  
Mirt Mehany
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Three Dimensional ◽  
Fused Deposition Modelling ◽  
Average Surface Roughness ◽  
Empty Shell ◽  
Average Surface ◽  
Fused Deposition ◽  
Resolution Parameter ◽  
Printing Processes

The ability to use different parameters and finishing techniques in fused deposition modelling (FDM) depends largely on part geometries, materials, printing processes like Z-resolution and post processing to some extent. Low quality poor surface finish due to layer ovality, improper Z-resolution parameter selection and fill of the empty shell in three-dimensional (3D) printing, results unexpected texture and appearance. An investigation is carried out on the effects of Z-resolution (0.15 mm to 0.40 mm) and Fill parameters on flat and curved surface objects manufactured using the FDM process. Moreover, post surface treatment was performed using acetone. It was found that average surface roughness increases with increasing Z-resolution. Solid Fill can create a smoother surface as oppose to Sparse Fill. Surface roughness improves significantly after post treatment with organic solvent acetone.

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.

A multi-criteria decision making method for vapor smoothening fused deposition modelling part

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sugavaneswarn M. ◽  
Prashanthi B. ◽  
John Rajan A.
Keyword(s):  
Decision Making ◽  
Surface Roughness ◽  
Process Parameters ◽  
Surface Finish ◽  
Orientation Angle ◽  
Multi Criteria Decision Making ◽  
Post Processing ◽  
Dimensional Error ◽  
Content Type ◽  
Fused Deposition

Purpose This paper aims to enhance the surface finish of the fused deposition modeling (FDM) part using the vapor smoothening (VS) post-processing method and to study the combined effect of FDM and VS process parameters on the quality of the part. Design/methodology/approach Analysis of variance method is used to understand the significance of the FDM and VS process parameters. Following this, the optimized parameter for multiple criteria response is reported using the technique for order preference by similarity to ideal solution. The process parameters alternatives are build orientation angle, build surface normal and exposure time and the criteria are surface roughness and dimensional error percentage. Findings The result observed contradicts the result reported on the independent parameter optimization of FDM and VS processes. There is a radical improvement in the surface finish on account of the coating process and an increase in the exposure time results in the decrease of the surface roughness. Minimum surface roughness of 0.11 µm is observed at 1,620 build angle and the least dimensional error of 0.01% is observed at build orientation angle 540. The impact of VS on the up-facing surface is different from the down-facing surface due to the removal of support material burrs and the exposure of the surface to vapor direction. Originality/value A study on the multi-criteria decision-making to ascertain the effect of post-processing on FDM component surface normal directed both to downward (build angle 0°–90°) and to upward (build angle 99°–180°) are reported for the first time in this article. The data reported for the post-processed FDM part at the build angle 0°–180° can be used as a guideline for selecting the optimal parameter and for assigning appropriate tolerance in the CAD model.

scholarly journals COMBINING FUSED DEPOSITION MODELLING WITH ABRASIVE MILLING TO ATTAIN HIGHER DIMENSIONAL ACCURACY AND BETTER SURFACE FINISH ON THE FINISHED PRODUCT

2018 ◽  
Vol 19 (2) ◽  
pp. 221-231 ◽  
Author(s):  
A N M AMANULLAH TOMAL ◽  
Tanveer Saleh ◽  
Md. Raisuddin Khan
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Cnc Machining ◽  
Numerical Control ◽  
Fused Deposition Modelling ◽  
Numerical Control Machining ◽  
Fused Deposition ◽  
Higher Dimensional

ABSTRACT: Currently, two manufacturing methods, namely CNC (Computer Numerical Control) machining and rapid prototyping (RP), are widely used to produce final products and prototypes.  Both the processes have their own advantages. CNC machining such as milling and grinding (subtractive method) can fabricate parts with higher precision and accuracy. On the other hand, RP (additive method), can manufacture parts with complicated 3-D (three dimensional) features, which ensures effective material usage. However, RP produced parts lack accuracy and smooth surface finish. In this research, we are aiming to achieve on-machine mechanical post-processing of 3-D printed (using Fused Deposition Modelling, a kind of RP process) parts to achieve higher dimensional accuracy and better surface roughness. To achieve the goal, we developed a new hybrid system to assimilate both of these processes. There are, however, two vital considerations needed to be taken into account for integrating the two processes. The first concern is the integration of dissimilar control systems for two processes and the second aspect is maintaining the tools’ (milling spindle and the heat extruder) setup accuracy during the changeover step. The developed hybrid machine has been tested with experimentations and the result showed that the dimensional accuracy was improved by 71% to 99% when the FDM part was compared with the final part after abrasive milling operation. At the same time, average surface roughness (Ra) was improved up to 91.3%. Further, we found that low layer thickness improves the product quality. The proposed system could push the conventional FDM system to the next level to attain better quality of final products. ABSTRAK: Dua kaedah terkini proses pembuatan, dinamakan mesin Kawalan Komputer Bernombor (CNC) dan prototaip langsung (RP) telah digunakan secara meluas bagi menghasilkan produk dan prototaip. Kedua-dua proses mempunyai keistimewaan tersendiri. Mesin CNC seperti mesin penghasil permukaan dan mesin penebuk lubang (melalui kaedah pengurangan) dapat menghasilkan sesuatu bahagian dengan ketepatan tinggi. Pada sudut lain, RP (melalui kaedah penambahan), dapat menghasilkan bahagian dengan kaedah 3D (tiga dimensi) yang rumit tetapi berkesan dalam memaksimakan penggunaan material. Walau bagaimanapun, penghasilan bahagian melalui kaedah RP mempunyai kekurangan pada ketepatan dan kekurangan pada kekemasan permukaan akhir. Kajian ini bertujuan meraih ketepatan dimensi yang lebih tinggi dan kekemasan permukaan yang lebih bagus pada proses terakhir pada bahagian cetakan mesin mekanikal 3D (menggunakan Model Deposit Fuse iaitu salah satu proses RP). Bagi mencapai tujuan ini, kami menghasilkan sistem hibrid terbaru untuk mengasimulasi kedua-dua proses. Walau bagaimanapun, terdapat dua perkara penting perlu diambil kira untuk diintegrasi bersama kedua-dua proses. Penilaian pertama adalah pada sistem kawalan tidak serupa, dan kedua pada aspek pengekalan alat (gelendung pemutar dan kepanasan pembentuk) ketepatan penyediaan semasa peringkat perubahan. Mesin hibrid yang dicipta telah diuji melalui eksperimentasi dan keputusan menunjukkan ketepatan dimensi telah bertambah daripada 71% kepada 99% semasa bahagian FDM dibandingkan dengan bahagian akhir selepas operasi putaran kasar. Pada masa sama, purata permukaan kasar (Ra) telah bertambah kepada 91.3%. Kami juga mendapati ketebalan lapisan bawah telah menambah baik kualiti produk. Sistem yang dicadangkan dapat mengubah sistem FDM konvensional kepada peringkat lebih tinggi bagi memperolehi kualiti terbaik pada produk akhir.

scholarly journals Experimental investigation and ANN prediction for part quality improvement of fused deposition modeling parts

2021 ◽  
Vol 1201 (1) ◽  
pp. 012031
Author(s):  
A D Tura ◽  
H B Mamo ◽  
Y D Jelila ◽  
H G Lemu
Keyword(s):  
Surface Roughness ◽  
Fused Deposition Modeling ◽  
Orientation Angle ◽  
Percentage Error ◽  
Part Quality ◽  
Fused Deposition ◽  
Input Parameters ◽  
Deposition Modeling ◽  
Process Factors ◽  
The Impact

Abstract Fused deposition modeling (FDM) is the most prevalent thermoplastic additive manufacturing technology. Many input parameters and their settings have a significant impact on the quality and functionality of FDM parts produced. To enhance the quality of parts, it is critical to be able to predict surface roughness distribution in advance. The development of artificial neural network (ANN) models to forecast the impact of main FDM process factors on the part quality in terms of surface roughness while utilizing ABS (Acrylonitrile butadiene styrene) material is described in this work. Taguchi L9 orthogonal array was used to plan the experiments. Different printing input parameters such as layer thickness, orientation angle, and infill angle are used in the experiments. In terms of controllable input parameters, ANN is used to construct a predictive mathematical model. The effects of various printing settings on surface roughness were investigated using analysis of variance (ANOVA), main effect plots, and contour plots. Experiment findings and regression value are used to validate the models. The model has shown to be capable of adequately predicting responses within a maximum percentage error of 4.664 percent of arithmetic roughness average (Ra), which is a good agreement.

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