scholarly journals An experimental investigation of viscosity of a newly developed natural polymer-based media for abrasive flow machining (AFM) of 3D printed ABS parts

2021 ◽  
Author(s):  
Abdul Wahab Hashmi ◽  
◽  
Harlal Singh Mali ◽  
Anoj Meena ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Base Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Natural Polymer ◽  
Rheological Analysis ◽  
Abrasive Flow Machining ◽  
3D Printed ◽  
Parametric Dependencies ◽  
Waste Polymer

Abrasive Flow Machining (AFM) is the method of finishing complex surfaces and internal channels with the help of extrusion pressure and abrasive-laden viscoelastic polymer media. This paper is based on developing a new AFM media using a natural waste polymer as a base material. In the article, a natural polymer media viz. rice husk ash-based media has been developed, and subsequently, rheological analysis has been done, and experimentation has been performed on Anton-paar® rheometer to optimize the viscosity of these newly developed AFM media. In this research study, the hollow elliptical shape of ABS (acrylonitrile-butadiene-styrene) material was manufactured using the FDM technique and then finished with a one-way AFM machine. This paper examined the parametric dependencies of AFM process parameters on finishing FDM printed hollow elliptical parts. The improved surface roughness of the FDM printed hollow elliptical parts has been investigated relating to the AFM process parameters. The maximum surface roughness has been achieved by 95.98%.

Experimental investigations into abrasive flow machining (AFM) of 3D printed ABS and PLA parts

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nitin Dixit ◽  
Varun Sharma ◽  
Pradeep Kumar
Keyword(s):  
Surface Roughness ◽  
Biomedical Applications ◽  
Fused Deposition Modeling ◽  
Experimental Investigations ◽  
Future Research ◽  
Content Type ◽  
Abrasive Flow Machining ◽  
Fused Deposition ◽  
Cylindrical Parts ◽  
3D Printed

Purpose The surface roughness of additively manufactured parts is usually found to be high. This limits their use in industrial and biomedical applications. Therefore, these parts required post-processing to improve their surface quality. The purpose of this study is to finish three-dimensional (3D) printed acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) parts using abrasive flow machining (AFM). Design/methodology/approach A hydrogel-based abrasive media has been developed to finish 3D printed parts. The developed abrasive media has been characterized for its rheology and thermal stability using sweep tests, thermogravimetric analysis (TGA) and differential thermal analysis (DTA). The ABS and PLA cylindrical parts have been prepared using fused deposition modeling (FDM) and finished using AFM. The experiments were designed using Taguchi (L9 OA) method. The effect of process parameters such as extrusion pressure (EP), layer thickness (LT) and abrasive concentration (AC) was investigated on the amount of material removed (MR) and percentage improvement in surface roughness (%ΔRa). Findings The developed abrasive media was found to be effective for finishing FDM printed parts using AFM. The microscope images of unfinished and finished showed a significant improvement in surface topography of additively manufactures parts after AFM. The results reveal that AC is the most significant parameter during the finishing of ABS parts. However, EP and AC are the most significant parameters for MR and %ΔRa, respectively, during the finishing of PLA parts. Practical implications The FDM technology has applications in the biomedical, electronics, aeronautics and defense sectors. PLA has good biodegradable and biocompatible properties, so widely used in biomedical applications. The ventilator splitters fabricated using FDM have a profile similar to the shape used in the present study. Research limitations/implications The present study is focused on finishing FDM printed cylindrical parts using AFM. Future research may be done on the AFM of complex shapes and freeform surfaces printed using different additive manufacturing (AM) techniques. Originality/value An abrasive media consists of xanthan gum, locust bean gum and fumed silica has been developed and characterized. An experimental study has been performed by combining printing parameters of FDM and finishing parameters of AFM. A comparative analysis in MR and %ΔRa has been reported between 3D printed ABS and PLA parts.

Analysis and Optimization of Process Parameters of Abrasive Flow Machining Process for Super Finishing of Non-Ferrous Material Nozzle

2014 ◽  
Vol 612 ◽  
pp. 97-104 ◽  
Author(s):  
Vijay B. Patil ◽  
Amol S. Bhanage ◽  
Rajat S. Patil
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
New Technology ◽  
Mesh Size ◽  
Flow Speed ◽  
Machining Process ◽  
Plasma Cutting ◽  
Abrasive Flow Machining ◽  
Number Of Cycles ◽  
Hierarchy Process

This paper deals with the improving lay of finish and the superfinishing of the nozzles which is used in plasma cutting operation. This is basically alternative solution to present finish obtained by turning, drilling and reaming of the profiled bores and orifices. The advance micromachining process were developed, known as Abrasive Flow Machining (AFM) which is capable to altering the orifice (nozzle of plasma cutting machines) so that present process is to be improved without altering the geometry of the component. The effects of different process parameters such as number of cycles, concentration of abrasive, abrasive mesh size and media flow speed, surface finish are studied here. The design of the experiments 16(24) provides two levels for each variable. These levels are taken into consideration for finding out the effect of variation of parameters on the surface roughness of the copper orifice. The objective of paper is to learn how each parameter is considered for Abrasive Flow Machining such as: abrasive concentration in media, number of cycles, abrasive mesh size and media flow speed affects the surface roughness of copper orifice also to find out the mathematical relationship between surface roughness value and process parameters. Analysis of Variance (ANOVA) for the experimental data has been carried out and optimizations of abrasive flow machining process parameters were done. Also Analytic Hierarchy Process (AHP) done here for selecting hierarchy process parameter .Capabilities of the machine ultimately improved with the new technology developed.

scholarly journals Preliminary Study on Polishing SLA 3D-Printed ABS-Like Resins for Surface Roughness and Glossiness Reduction

Micromachines ◽  
2020 ◽  
Vol 11 (9) ◽  
pp. 843
Author(s):  
Jungyu Son ◽  
Hyunseop Lee
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Acrylonitrile Butadiene Styrene ◽  
Machining Processes ◽  
Surface Machining ◽  
One Step ◽  
3D Printed ◽  
Printed Materials ◽  
The One ◽  
Considerable Period

After the development of 3D printing, the post-processing of the 3D-printed materials has been continuously studied, and with the recent expansion of the application of 3D printing, interest in it is increasing. Among various surface-machining processes, chemical mechanical polishing (CMP) is a technology that can effectively provide a fine surface via chemical reactions and mechanical material removal. In this study, two polishing methods were evaluated for the reduction of surface roughness and glossiness of a stereolithography apparatus (SLA) 3D-printed ABS (acrylonitrile butadiene styrene)-like resin. Experiments were conducted on the application of CMP directly to the 3D-printed ABS-like resin (one-step polishing), and on the application of sanding (#2000) and CMP sequentially (two-step polishing). The one-step polishing experiments showed that it took a considerable period of time to remove waviness on the surface of the as-3D printed specimen using CMP. However, in the case of two-step polishing, surface roughness was reduced, and glossiness was increased faster than in the case of one-step polishing via sanding and CMP. Consequently, the experimental results show that the two-step polishing method reduced roughness more efficiently than the one-step polishing method.

Experimental Study of the Effect of Post Processing Techniques on Mechanical Properties of Fused Deposition Modelled Parts

2015 ◽  
Vol 5 (1) ◽  
pp. 1-20 ◽  
Author(s):  
Addanki Sambasiva Rao ◽  
Medha A. Dharap ◽  
J. V. L. Venkatesh
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Chemical Treatment ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Treatment Method ◽  
Time Layer ◽  
Fused Deposition ◽  
Chemically Treated ◽  
Izod Impact

FDM (Fused Deposition Modelled) parts are chemically treated with two types of chemicals viz Dimethyl ketone (Acetone) and Methyl ethyl ketone to reduce the surface roughness. This chemical treatment method technique not only reduces surface roughness but also makes effect on strength of chemically treated parts of ABS (Acrylonitrile Butadiene Styrene) material. In this study Taguchi method of DOE (Design of Experiments) is conducted on test specimen of “tensile”, “bending” and “izod impact” components which are manufactured through Fused Deposition Modeling process using ABS-P400 material. DOE is conducted to optimize the effect of chemical treatment process parameters on strength of above specimen parts. The process parameters considered for the DOE are “different levels of concentration of chemical, temperature, time, layer thickness etc. ANOVA (Analysis of variance) is used to know the significance of contribution of each of these parameters. Results reveal that the prototypes when treated at optimum condition the tensile strength, flexural strength and izod impact strength improved significantly.

3D Printed Cellular Structure Materials Under Impact and Compressive Loading

2020 ◽  
Author(s):  
Mahmoud K. Ardebili ◽  
Kerim Tuna Ikikardaslar ◽  
Colt Ehrnfeld ◽  
Feridun Delale
Keyword(s):  
Energy Absorption ◽  
Impact Energy ◽  
Lattice Structure ◽  
Base Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Structure Design ◽  
Impact Testing ◽  
Lateral Direction ◽  
Stacking Order ◽  
3D Printed

Abstract Advances in field of lattice structure design has become possible mainly due to the emerging capabilities of additive manufacturing (AM) or 3D printing. Lattices have the potential to reduce solid volumes, giving advantages such as weight reduction, decreased part production cost and ability to absorb energy under compressive and impact loading. These materials are anisotropic due to structural geometry and the additive nature of 3D-printed layers, which stack mainly in Normal or Lateral direction to the applied load. In this study 3D printed materials were fabricated that are nearly isotropic and are also lighter than base material. The lattice structure was formed using strut-based cell topologies that are adjoined as tetrahedrons. Two different tetrahedron density specimens were produced with Acrylonitrile Butadiene Styrene (ABS) using a Fusion Deposition Modelling (FDM) printer. The fabricated specimens were then tested for impact and compression capabilities. For comparison purposes, solid specimens with the same overall dimensions and highest infill ratio were also produced and tested. After compression and impact testing, results indicated that solid specimens’ impact energy absorption is higher with lateral stacking order relative to load, and compression resistance is higher for normal stacking order. The tetrahedron-filled specimens exhibited minimal stacking directional dependency and the higher count tetrahedron specimens provided more impact energy absorption and more resistance to compression than the lower count one. The normalization of specimens with respect to their weight indicated high density tetrahedron specimens’ impact energy absorption is nearly equal to that of solid specimens’. These results are initial steps in creating lattice structured materials that are isotropic, lighter and stronger than the base material.

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