Melt Flow Behavior of Metal Filled in Polymer Matrix for Fused Deposition Modeling (FDM) Filament

2014 ◽  
Vol 660 ◽  
pp. 84-88 ◽  
Author(s):  
Nasuha Sa'ude ◽  
Mustaffa Ibrahim ◽  
Mohd Halim Irwan Ibrahim
Keyword(s):  
Polymer Matrix ◽  
Fused Deposition Modeling ◽  
Plastic Material ◽  
Flow Behavior ◽  
Acrylonitrile Butadiene Styrene ◽  
Melt Flow ◽  
Element Analysis ◽  
Fused Deposition ◽  
Ansys Cfx ◽  
Exit Nozzle

This paper presents the melt flow behavior (MFB) of an acrylonitrile butadiene styrene (ABS), Polyproplene (PP), Polylactic Acid (PLA), ABS mix 10% Copper and ABS mix 10% Iron in the simulation. In this study, the effect MFB of ABS mix with 10% Iron and 10% Copper material was investigated based on the viscosity, density, thermal conductivity, melting temperature and specific heat of material properties. The MFB of metal filled in polymer matrix composite (PMC) through the FDM nozzle was investigated using Finite-Element Analysis (ANSYS CFX 12). Based on the result obtained, pressure outlet of mix ABS copper and ABS iron in extruder nozzle was higher value compared with others plastic material. The velocity was increased since the nozzle diameter is smaller than the entrance diameter. It can be observed that, the melt flow behavior of metal filled in PMC are affected on pressure drop, velocity and the nozzle size at the exit nozzle.

Melt Flow Behavior of Polymer Matrix Extrusion for Fused Deposition Modeling (FDM)

2014 ◽  
Vol 660 ◽  
pp. 89-93 ◽  
Author(s):  
Nasuha Sa'ude ◽  
Mustaffa Ibrahim ◽  
Mohd Halim Irwan Ibrahim
Keyword(s):  
Fused Deposition Modeling ◽  
Flow Behavior ◽  
Acrylonitrile Butadiene Styrene ◽  
Extrusion Process ◽  
Melt Flow ◽  
Element Analysis ◽  
Fused Deposition ◽  
Ansys Cfx ◽  
Deposition Modeling ◽  
Higher Temperature

This paper presents the melt flow behavior (MFB) of an acrylonitrile butadiene styrene (ABS), High Density Polyethlene (HDPE), Polyproplene (PP) and a combination of ABS-Iron in the extrusion process. In this study, the effect MFB of variety's polymers and ABS mix with 10% Iron material was investigated based on the viscosity, density, thermal conductivity, melting temperature and specific heat material properties. The MFB of FDM system was investigated using Finite-Element Analysis (FEA) by ANSYS CFX 12. Based on the result obtained, it was found that, the material velocity increase when the nozzle diameter is smaller than the entrance diameter. The higher temperature distribution along the MFB of ABS mix with 10% Iron is 43.15 K compared with original ABS, which is 539.15K.

scholarly journals Design of Self-Supported 3D Printed Parts for Fused Deposition Modeling

2016 ◽  
Author(s):  
Fabian Lischke ◽  
Andres Tovar
Keyword(s):  
Numerical Model ◽  
Fused Deposition Modeling ◽  
Beam Theory ◽  
Critical Factor ◽  
Acrylonitrile Butadiene Styrene ◽  
Material Model ◽  
Analytical Models ◽  
Element Analysis ◽  
Fused Deposition ◽  
3D Printed

One of the primary challenges faced in Additive Manufacturing (AM) is reducing the overall cost and printing time. A critical factor in cost and time reduction is post-processing of 3D printed (3DP) parts, of which removing support structures is one of the most time consuming steps. Support is needed to prevent the collapse of the part or certain areas under its own weight during the 3D printing process. Currently, the design of self-supported 3DP parts follows a set of empirical guide lines. A trial and error process is needed to produce high quality parts by Fused Depositing Modeling (FDM). The usage of chamfer angle with a max 45° angle form the horizontal for FDM is a common example. Inclined surfaces with a smaller angle are prone to defects, however no theoretical basis has been fully defined, therefore a numerical model is needed. The model can predict the problematic areas at a print, reducing the experimental prints and providing a higher number of usable parts. Physical-based models have not been established due to the generally unknown properties of the material during the AM process. With simulations it is possible to simulate the part at different temperatures with a variety of other parameters that have influence on the behavior of the model. In this research, analytic calculations and physical tests are carried out to determine the material properties of the thermoplastic polymer Acrylonitrile - Butadiene - Styrene (ABS) f or FDM at the time of extrusion. This means that the ABS is going to be extruded at 200°C to 245°C and is a viscous material during part construction. Using the results from the physical and analytical models, i.e., Timoshenko’s modified beam theory for micro-structures, a numerical material model is established to simulate the filament deformation once it is deposited onto the part. Experiments were also used to find the threshold for different geometric specifications, which could then be applied to the numerical model to improve the accuracy of the simulation. The result of the finite element analysis is compared to experiments to show the correlation between the prediction of deflection in simulation and the actual deflection measured in physical experiments. A case study was conducted using an application that optimizes topology of complex geometries. After modeling and simulating the optimized part, areas of defect and errors were determined in the simulation, then verified and and measured with actual 3D prints.

scholarly journals A Study on Melt Flow Index on Copper-ABS for Fused Deposition Modeling (FDM) Feedstock

2015 ◽  
Vol 773-774 ◽  
pp. 8-12 ◽  
Author(s):  
Noor Mu'izzah Ahmad Isa ◽  
Nasuha Sa'ude ◽  
M. Ibrahim ◽  
Saiful Manar Hamid ◽  
Khairu Kamarudin
Keyword(s):  
Injection Molding ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Melt Flow Index ◽  
Internal Force ◽  
Flow Index ◽  
Fused Deposition Modelling ◽  
Melt Flow ◽  
Volume Percentage ◽  
Fused Deposition

This paper presents of Polymer Matrix Composite (PMC) as feedstock used in Fused Deposition Modelling (FDM) machine. This study discussed on the development of a new PMC material by the injection molding machine. The material consist of copper powder filled in an acrylonitrile butadiene styrene (ABS), binder and surfactant material. The effect of metal filled in ABS and binder content was investigated experimentally by the Melt Flow Index (MFI) machine. Based on the result obtained, an increment of copper filled in ABS by volume percentage (vol. %) effected on melt flow index results. With highly filled copper in PMC composites increase the melt flow index results. It was concluded that, the propensity of the melt flow allow an internal force in PMC material through the injection molding and FDM machine.

scholarly journals Additive Technology Parts and their Material Properties

2019 ◽  
Vol 16 (1) ◽  
pp. 58-61
Author(s):  
Juraj Beniak ◽  
Miloš Matúš ◽  
Peter Križan ◽  
Michal Holdy
Keyword(s):  
Fused Deposition Modeling ◽  
Plastic Material ◽  
Acrylonitrile Butadiene Styrene ◽  
Additive Technology ◽  
Modeling Technology ◽  
Fused Deposition ◽  
Steel Material ◽  
Plastic Materials ◽  
Wide Range ◽  
Plastic Parts

Abstract Additive technology uses a wide range of materials. Beginning from plastic material, different types of resin but also steel material. Presented paper deals with Fused Deposition Modeling technology which is focused to processing of plastic materials based on polymers. Mostly used are ABS plastic (Acrylonitrile Butadiene Styrene), Nylon, Polycarbonate (PC), or composites based on different polymers. New devices designed for the production of plastic parts are able to work also with environmentally friendly and biodegradable materials as Polylactic acid (PLA). The aim of this paper is to show the possibility of using materials based on organic polymers whose properties are comparable to conventionally used polymers. Presented are measured and statistically evaluated data related to basic properties of PLA material.

scholarly journals Melt Flow Index of Recycle ABS for Fused Deposition Modeling (FDM) Filament

2015 ◽  
Vol 773-774 ◽  
pp. 3-7 ◽  
Author(s):  
Nasuha Sa'ude ◽  
Khairu Kamarudin ◽  
Mustaffa Ibrahim ◽  
Mohd Halim Irwan Ibrahim
Keyword(s):  
Material Properties ◽  
Fused Deposition Modeling ◽  
Acrylonitrile Butadiene Styrene ◽  
Melt Flow Index ◽  
Flow Index ◽  
Melt Flow ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Higher Temperature ◽  
Butadiene Styrene

This paper presents the melt flow index (MFI) of acrylonitrile butadiene styrene (ABS) and recycle ABS filament wire for Fused Deposition Modeling (FDM) machine. In this study, the effect of MFI on recycle ABS material was investigated experimentally based on the melting temperature, density, screw speed and material properties. The MFI result on ABS recycle in wire filament was investigated using Melt Indexer Machine (MIM). Based on the result obtained, it was found that, ABS recycle was increase the density and MFI results. It can be observed that, the higher temperature was melt the recycle ABS material through the MIM and extruder machine.

Mechanical, thermal and melt flow of aluminum-reinforced PA6/ABS blend feedstock filament for fused deposition modeling

2018 ◽  
Vol 24 (9) ◽  
pp. 1455-1468 ◽  
Author(s):  
Rupinder Singh ◽  
Ranvijay Kumar ◽  
IPS Ahuja
Keyword(s):  
Thermal Properties ◽  
Polymer Matrix ◽  
Friction Welding ◽  
Fused Deposition Modeling ◽  
Flow Index ◽  
Melt Flow ◽  
Content Type ◽  
Fused Deposition ◽  
Feed Stock ◽  
Deposition Modeling

Purpose This study aims to highlights the mechanical, thermal and melting behavior compatibility of aluminum (Al)-reinforced polyamide (PA) 6/acrylonitrile butadiene styrene (ABS)-based functional prototypes prepared using fused deposition modeling (FDM) from the friction welding point of view. Previous studies have highlighted the use of metallic/non-metallic fillers in polymer matrix for preparations of mechanically improved FDM feedstock filaments and functional prototypes. But hitherto, very less has been reported on fabrication of functional prototypes which fulfill the compatibility of two polymers for joining/welding-based applications. The compatibility of two dissimilar polymers enables the friction welding for maintenance applications. Design/methodology/approach The twin screw extrusion process has been used for mechanical mixing of metallic reinforcement in polymer matrix, and final blend of reinforced polymers in the form of extruded feed stock filament has been used on FDM for printing of functional prototypes (for friction welding). The methodology involves melt flow index (MFI) investigations, differential scanning calorimetry (DSC) investigations for thermal properties, tensile and hardness testing for mechanical properties and photo micrographic investigations for metallurgical properties on extruded samples. Findings It was observed that the reinforced ABS and PA6 polymers have better compatibility in the terms of similar melt flow, thermal properties and can lead to the better joint efficiency with friction welding. Originality/value In the present work composite feed stock filament composed of ABS and PA6 with reinforcement of Al powder has been successfully developed for preparation of functional prototype in friction welding applications.

scholarly journals Carbon Nanotube-Based Composite Filaments for 3D Printing of Structural and Conductive Elements

2021 ◽  
Vol 11 (3) ◽  
pp. 1272
Author(s):  
Bartłomiej Podsiadły ◽  
Piotr Matuszewski ◽  
Andrzej Skalski ◽  
Marcin Słoma
Keyword(s):  
Carbon Nanotubes ◽  
Fused Deposition Modeling ◽  
Supply Voltage ◽  
Acrylonitrile Butadiene Styrene ◽  
Structural Elements ◽  
Filling Fraction ◽  
Fused Deposition ◽  
Structural Electronics ◽  
Measured Sample ◽  
Deposition Modeling

In this publication, we describe the process of fabrication and the analysis of the properties of nanocomposite filaments based on carbon nanotubes and acrylonitrile butadiene styrene (ABS) polymer for fused deposition modeling (FDM) additive manufacturing. Polymer granulate was mixed and extruded with a filling fraction of 0.99, 1.96, 4.76, 9.09 wt.% of CNTs (carbon nanotubes) to fabricate composite filaments with a diameter of 1.75 mm. Detailed mechanical and electrical investigations of printed test samples were performed. The results demonstrate that CNT content has a significant influence on mechanical properties and electrical conductivity of printed samples. Printed samples obtained from high CNT content composites exhibited an improvement in the tensile strength by 12.6%. Measurements of nanocomposites’ electrical properties exhibited non-linear relation between the supply voltage and measured sample resistivity. This effect can be attributed to the semiconductor nature of the CNT functional phase and the occurrence of a tunnelling effect in percolation network. Detailed I–V characteristics related to the amount of CNTs in the composite and the supply voltage influence are also presented. At a constant voltage value, the average resistivity of the printed elements is 2.5 Ωm for 4.76 wt.% CNT and 0.15 Ωm for 9.09 wt.% CNT, respectively. These results demonstrate that ABS/CNT composites are a promising functional material for FDM additive fabrication of structural elements, but also structural electronics and sensors.

scholarly journals On the Post-Processing of 3D-Printed ABS Parts

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1559
Author(s):  
Mohammad Reza Khosravani ◽  
Jonas Schüürmann ◽  
Filippo Berto ◽  
Tamara Reinicke
Keyword(s):  
Surface Treatment ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Tests ◽  
Fracture Load ◽  
Post Processing ◽  
Fused Deposition ◽  
Dog Bone ◽  
3D Printed

Application of Additive Manufacturing (AM) has significantly increased in the past few years. AM also known as three-dimensional (3D) printing has been currently used in fabrication of prototypes and end-use products. Considering the new applications of additively manufactured components, it is necessary to study structural details of these parts. In the current study, influence of a post-processing on the mechanical properties of 3D-printed parts has been investigated. To this aim, Acrylonitrile Butadiene Styrene (ABS) material was used to produce test coupons based on the Fused Deposition Modeling (FDM) process. More in deep, a device was designed and fabricated to fix imperfection and provide smooth surfaces on the 3D-printed ABS specimens. Later, original and treated specimens were subjected to a series of tensile loads, three-point bending tests, and water absorption tests. The experimental tests indicated fracture load in untreated dog-bone shaped specimen was 2026.1 N which was decreased to 1951.7 N after surface treatment. Moreover, the performed surface treatment was lead and decrease in tensile strength from 29.37 MPa to 26.25 MPa. Comparison of the results confirmed effects of the surface modification on the fracture toughness of the examined semi-circular bending components. Moreover, a 3D laser microscope was used for visual investigation of the specimens. The documented results are beneficial for next designs and optimization of finishing processes.

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.

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