Evaluating the Mechanical Behavior of Fused Deposition Modeling Parameters of Raster Angle and Layer Thickness Effects on As-Built and Annealed Polymer Associated Composites

2021 ◽  
Author(s):  
Sivanesh Ari Gowder Ravi Kumar ◽  
Soundararajan R ◽  
Arivazhakan Dorai ◽  
Gopinath Suresh Kumar ◽  
Aravind Kumar Ramesh
Keyword(s):  
Mechanical Behavior ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Raster Angle ◽  
Deposition Modeling

OPTIMIZATION OF PROCESS PARAMETERS IN FUSED DEPOSITION MODELING USING WEIGHTED PRINCIPAL COMPONENT ANALYSIS

2011 ◽  
Vol 10 (02) ◽  
pp. 241-259 ◽  
Author(s):  
ANOOP KUMAR SOOD ◽  
VEDANSH CHATURVEDI ◽  
SAURAV DATTA ◽  
SIBA SANKAR MAHAPATRA
Keyword(s):  
Principal Component Analysis ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Principal Component ◽  
Air Gap ◽  
Fused Deposition ◽  
Raster Angle ◽  
Deposition Modeling ◽  
Single Response

Fused deposition modeling (FDM) is a process by which functional parts can be produced rapidly through deposition of fused layers of material according to a numerically defined cross-sectional geometry. Literature suggests that process parameters largely influence on quality characteristics of rapid prototyping (RP) parts. A functional part is subjected to different loading conditions in actual practice. Therefore, process parameters need to be determined in such a way that they collectively optimize more than one response simultaneously. To address this issue, effect of important process parameters viz., layer thickness, orientation, raster angle, raster width, and air gap have been studied. The responses considered in this study are mechanical property of FDM produced parts such as tensile, bending and impact strength. The multiple responses are converted into a single response using principal component analysis (PCA) so that influence of correlation among the responses can be eliminated. Resulting single response is nothing but the weighted sum of three principal components that explain almost hundred percent of variation. The experiments have been conducted in accordance with Taguchi's orthogonal array to reduce the experimental runs. The results indicate that all the factors such as layer thickness, orientation, raster angle, raster width and air gap and interaction between layer thickness and orientation significantly influence the response. Optimum parameter settings have been identified to simultaneously optimize three responses. The mechanism of failure is explained with the help of SEM micrographs.

Multiresponse Optimization of Fused Deposition Modeling Process Using Utility-Based Taguchi Approach

2018 ◽  
Vol 17 (04) ◽  
pp. 551-568 ◽  
Author(s):  
Saurabh Verma ◽  
Vedansh Chaturvedi
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Optimum Process ◽  
Utility Concept ◽  
Fused Deposition ◽  
Multiresponse Optimization ◽  
Raster Angle ◽  
Deposition Modeling ◽  
Part Orientation

Rapid Prototyping (RP) technology has become the powerful tool for product development in almost every branch of engineering. Many new and upcoming processes offer means for the fast creation of models with steadily increasing accuracy, built speed, other model properties and economic advantages. Fused Deposition Modeling (FDM) is the most famous and commercially available RP system. This paper presents the application of Utility concept with Taguchi method for multiresponse optimization of the FDM process. Stratatys Fortus 400[Formula: see text]mc FDM setup is used to conduct experiments as per Taguchi’s L9 orthogonal array. FDM parameters: Layer thickness, part orientation and raster angle were optimized based on multiple responses, i.e. tensile, flexural, impact and compressive strength. The optimum process parameters are calculated using utility concept. The Analysis of variance (ANOVA) is applied to find out the most significant factor. It has been found that layer thickness is the most significant factor, followed by part orientation and raster angle. The confirmation tests with optimal levels of process parameters are conducted to illustrate the efficacy of the proposed method. It is found that optimum combination of process parameters gives the highest utility value, which indicates that multiresponses of the FDM process can be improved through this approach.

scholarly journals Process Parameter Optimization in Fused Deposition Modeling (FDM) Using Response Surface Methodology (RSM)

2020 ◽  
Author(s):  
Muhammad Salman Mustafa ◽  
Muhammad Qasim Zafar ◽  
Muhammad Arslan Muneer ◽  
Muhammad Arif ◽  
Farrukh Arsalan Siddiqui ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Response Surface Methodology ◽  
Impact Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Experimental Results ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Printing Parameters

Abstract Fused Deposition Modeling (FDM) is a widely adopted additive manufacturing process to produce complex 3D structures and it is typically used in the fabrication of biodegradable materials e.g. PLA/PHA for biomedical applications. However, FDM as a fabrication process for such material needs to be optimized to enhance mechanical properties. In this study, dogbone and notched samples are printed with the FDM process to determine optimum values of printing parameters for superior mechanical properties. The effect of layer thickness, infill density, and print bed temperature on mechanical properties is investigated by applying response surface methodology (RSM). Optimum printing parameters are identified for tensile and impact strength and an empirical relation has been formulated with response surface methodology (RSM). Furthermore, the analysis of variance (ANOVA) was performed on the experimental results to determine the influence of the process parameters and their interactions. ANOVA results demonstrate that 44.7% infill density, 0.44 mm layer thickness, and 20C° printing temperatures are the optimum values of printing parameters owing to improved tensile and impact strength respectively. The experimental results were found in strong agreement with the predicted theoretical results.

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 layer thickness on irreversible thermal expansion and interlayer strength in fused deposition modeling

2017 ◽  
Vol 23 (5) ◽  
pp. 943-953 ◽  
Author(s):  
Anthony A. D’Amico ◽  
Analise Debaie ◽  
Amy M. Peterson
Keyword(s):  
Mechanical Properties ◽  
Thermal Expansion ◽  
Flexural Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Thermal Strain ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
The Impact

Purpose The aim of this paper is to examine the impact of layer thickness on irreversible thermal expansion, residual stress and mechanical properties of additively manufactured parts. Design/methodology/approach Samples were printed at several layer thicknesses, and their irreversible thermal expansion, tensile strength and flexural strength were determined. Findings Irreversible thermal strain increases with decreasing layer thickness, up to 22 per cent strain. Tensile and flexural strengths exhibited a peak at a layer thickness of 200 μm although the maximum was not statistically significant at a 95 per cent confidence interval. Tensile strength was 54 to 97 per cent of reported values for injection molded acrylonitrile butadiene styrene (ABS) and 29 to 73 per cent of those reported for bulk ABS. Flexural strength was 18 to 41 per cent of reported flexural strength for bulk ABS. Practical implications The large irreversible thermal strain exhibited that corresponding residual stresses could lead to failure of additively manufactured parts over time. Additionally, the observed irreversible thermal strains could enable thermally responsive shape in additively manufactured parts. Variation in mechanical properties with layer thickness will also affect manufactured parts. Originality/value Tailorable irreversible thermal strain of this magnitude has not been previously reported for additively manufactured parts. This strain occurs in parts made with both high-end and consumer grade fused deposition modeling machines. Additionally, the impact of layer thickness on tensile and flexural properties of additively manufactured parts has received limited attention in the literature.

scholarly journals Preparation of Hydrophobic Surface on PLA and ABS by Fused Deposition Modeling

Polymers ◽  
2020 ◽  
Vol 12 (7) ◽  
pp. 1539 ◽  
Author(s):  
Huadong Yang ◽  
Fengchao Ji ◽  
Zhen Li ◽  
Shuai Tao
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Hydrophobic Coatings ◽  
Fused Deposition ◽  
Filling Method ◽  
Deposition Modeling ◽  
Experiment Analysis ◽  
Printing Speed

In the fields of agriculture, medical treatment, food, and packaging, polymers are required to have the characteristics of self-cleaning, anti-icing, and anti-corrosion. The traditional preparation method of hydrophobic coatings is costly and the process is complex, which has special requirements on the surface of the part. In this study, fused deposition modeling (FDM) 3D printing technology with design and processing flexibility was applied to the preparation of hydrophobic coatings on polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) parts, and the relationship between the printing process parameters and the surface roughness and wettability of the printed test parts was discussed. The experimental results show that the layer thickness and filling method have a significant effect on the surface roughness of the 3D-printed parts, while the printing speed has no effect on the surface roughness. The orthogonal experiment analysis method was used to perform the wettability experiment analysis, and the optimal preparation process parameters were found to be a layer thickness of 0.25 mm, the Grid filling method, and a printing speed of 150 mm/s.

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