Process–Property Relationships for Fused Filament Fabrication on Preexisting Polymer Substrates

2018 ◽  
Vol 140 (8) ◽  
Author(s):  
Harry A. Pierson ◽  
Bharat Chivukula
Keyword(s):  
Surface Roughness ◽  
Bond Strength ◽  
Layer Thickness ◽  
Process Parameters ◽  
Optimal Parameter ◽  
Fused Filament Fabrication ◽  
Highly Sensitive ◽  
Raster Angle ◽  
Process Property ◽  
Five Axis

Recent advances in fused filament fabrication (FFF), such as five-axis printing, patching existing parts, and certain hybrid manufacturing processes, involve printing atop a previously manufactured polymer substrate. The success of these technologies depends upon the bond strength between the substrate and the newly added geometry. ANOVA and response surface methods were used to determine the effect of three process parameters on bond tensile strength: surface roughness, layer thickness, and raster angle. Experimental results indicate that the process–property relationships are not identical to those found in single, continuous FFF operations, and that the physical bonding mechanisms may also be different. Bond strength was found to be highly sensitive to surface roughness and layer thickness, and distinct optimal parameter settings exist. These results represent a first step toward understanding bond strength in such circumstances, allowing manufacturers to intelligently select process parameters for the production of both the substrate and the secondary geometry.

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.

Studies Regarding the Influence on the Surface Roughness Material of the Cutting Regime during the Milling Processing

2015 ◽  
Vol 1128 ◽  
pp. 271-281 ◽  
Author(s):  
Mihai Demian ◽  
Luminita Grecu ◽  
Gabriela Demian
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Optimal Parameter ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Error Variance ◽  
Milling Process ◽  
Depth Of Cut ◽  
Low Level ◽  
First Case

The aim of the present paper is to establish the optimal parameter values of the cutting regime of a milling process. The paper presents a study regarding the influence of the cutting parameters on the surface roughness of the material and also on the vibration generated by their combinations, during a processing by milling. The studies are made on samples made from S355 JR steel with a metal milling machine FUS 25, which is used also for the experiments. The samples dimensions are 210x150x16mm. For the experiments there was used a cylindrical - frontal milling tool, with 32mm diameter and 10 tooth. Basic parameters of milling processing of materials we have considered in this paper are: feed rate [mm/min]; cutting speed RPM [rot/min]; depth of cut [mm]. For each of this parameters three levels were envisaged. For a 100% accurate experiment results at least 27 experiments must be done. Using an L9 orthogonal array, the number of experiments is reduced to nine and the accurate of the method is around 99.96%. The optimal process parameters values are obtained using Taguchi method considering three situations. In the first case the goal is to get only a fine roughness for the sample. The second studied case is focused on finding a low level for the vibration generated during the milling process. The aim of the last study is to find a fine roughness and also a low level of vibration for the process. The analysis of variance (ANOVA) is applied, in all cases, in order to estimate the error variance and to rank the process parameters according to their importance.

scholarly journals Identification of Optimal Process Parameter Settings Based on Manufacturing Performance for Fused Filament Fabrication of CFR-PEEK

2020 ◽  
Vol 10 (13) ◽  
pp. 4630
Author(s):  
Kijung Park ◽  
Gayeon Kim ◽  
Heena No ◽  
Hyun Woo Jeon ◽  
Gül E. Okudan Kremer
Keyword(s):  
Layer Thickness ◽  
Optimal Parameter ◽  
Lower Layer ◽  
Critical Role ◽  
Performance Measure ◽  
Fused Filament Fabrication ◽  
Trade Offs ◽  
Manufacturing Performance ◽  
Overall Performance ◽  
The Impact

Fused filament fabrication (FFF) has been proven to be an effective additive manufacturing technique for carbon fiber reinforced polyether–ether–ketone (CFR-PEEK) due to its practicality in use. However, the relationships between the process parameters and their trade-offs in manufacturing performance have not been extensively studied for CFR-PEEK although they are essential to identify the optimal parameter settings. This study therefore investigates the impact of critical FFF parameters (i.e., layer thickness, build orientation, and printing speed) on the manufacturing performance (i.e., printing time, dimensional accuracy, and material cost) of CFR-PEEK outputs. A full factorial design of the experiments is performed for each of the three sample designs to identify the optimal parameter combinations for each performance measure. In addition, multiple response optimization was used to derive optimal parameter settings for the overall performance. The results show that the optimal parameter settings depend on the performance measures regardless of the designs, and that the layer thickness plays a critical role in the performance trade-offs. In addition, lower layer thickness, horizontal orientation, and higher speed form the optimal settings to maximize the overall performance. The findings from this study indicate that FFF parameter settings for CFR-PEEK should be identified through multi-objective decision making that involves conflicts between the operational objectives for the parameter settings.

Tailoring physico-mechanical properties and rheological behavior of ABS filaments for FDM via blending with SEBS TPE

2020 ◽  
Vol 26 (10) ◽  
pp. 1687-1700
Author(s):  
Mozhgan Sayanjali ◽  
Amir Masood Rezadoust ◽  
Foroud Abbassi Sourki
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
3D Printing ◽  
Impact Strength ◽  
Layer Thickness ◽  
Melt Mixing ◽  
Content Type ◽  
Build Orientation ◽  
Raster Angle ◽  
The Impact

Purpose This paper aims to focus on the development of the three-dimensional (3D) printing filaments based on acrylonitrile butadiene styrene (ABS) copolymer and styrene-ethylene/butylene-styrene (SEBS) block copolymer, with tailored viscoelastic properties and controlled flow during the 3D printing process. Design/methodology/approach In this investigation, ABS was blended with various amounts of SEBS via a melt mixing process. Then the ABS/SEBS filaments were prepared by a single-screw extruder and printed by the FDM method. The rheological properties were determined using an MCR 501 from Anton-Paar. The melt flow behavior of ABS/SEBS filaments was determined. The morphology of the filaments was studied by scanning electron microscope and the mechanical (tensile and impact) properties, surface roughness and void content of printed samples were investigated. Findings The rheological results can accurately interpret what drives the morphology and mechanical properties’ changes in the blends. The impact strength, toughness, elongation-at-break and anisotropy in mechanical properties of ABS samples were improved concurrently by adding 40 Wt.% of SEBS. The optimal tensile properties of blend containing 40 Wt.% SEBS samples were obtained at −45°/+45° raster angle, 0.05 mm layer thickness and XYZ build orientation. Optimized samples showed an 890% increase in elongation compared to neat ABS. Also, the impact strength of ABS samples showed a 60% improvement by adding 40 Wt.% SEBS. Originality/value The paper simultaneously evaluates the effects of material composition and 3D printing parameters (layer thickness, raster angle and build orientation) on the rheology, morphology, mechanical properties and surface roughness. Also, a mechanical properties comparison between printed samples and their compression-molded counterpart was conducted.

Influence of processing parameters on creep and recovery behavior of FDM manufactured part using definitive screening design and ANN

2017 ◽  
Vol 23 (6) ◽  
pp. 998-1010 ◽  
Author(s):  
Omar Ahmed Mohamed ◽  
Syed Hasan Masood ◽  
Jahar Lal Bhowmik
Keyword(s):  
Layer Thickness ◽  
Process Parameters ◽  
Air Gap ◽  
Content Type ◽  
Screening Design ◽  
Definitive Screening ◽  
Raster Angle ◽  
Road Width ◽  
Recoverable Compliance ◽  
The Relationship

Purpose The purpose of this paper is to investigate the effect of process parameters of fused deposition modelling (FDM) 3D printing process on viscoelastic responses (creep compliance and recoverable compliance) of FDM built parts using a novel experimental design technique. Design/methodology/approach As part of the process characterization, a recently developed class of three-level design methodology – definitive screening design (DSD) – was used in this study to fit a second-order polynomial regression model. Artificial neural network (ANN) was also used to determine the optimal process parameters to improve creep compliance and recoverable compliance. The relationship between layer thickness, air gap, raster angle, build orientation, road width, number of contours and creep performance of FDM fabricated part was thereafter established empirically. Scanning electron microscope (SEM) is used to examine and characterize the morphology of the structures for some samples. Findings This study found that the creep resistance of FDM-manufactured part is significantly influenced by layer thickness, air gap, raster angle and number of contours and it can be improved by optimizing the settings of the selected parameters. The relationship between FDM process parameters and creep properties was determined, with the best creep performance observed by using 0.127 mm of layer thickness, zero air gap, zero raster angle, build orientation of 17.188°, road width of 0.4572 mm and 10 contours. Finally, the result is verified by confirmation experiments. The results prove that a DSD is a very effective design in characterizing the influence of process parameters on creep properties of FDM-built part at the lowest cost. Originality/value The originality of this paper lies in characterizing and optimizing the effect of process parameters on creep performance of FDM manufactured part that has not been studied in all previous studies. The paper highlights, for the first time, how the application of DSD can overcome most of the limitations encountered in the conventional techniques. This study can be used as a guide to the different additive manufacturing users of various industries and the results provide a good technical database on how FDM process parameters influence the creep performance of manufactured parts.

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.

Experimental investigations on surface integrity issues of Inconel-690 during wire-cut electrical discharge machining process

2016 ◽  
Vol 232 (4) ◽  
pp. 731-741 ◽  
Author(s):  
M Sreenivasa Rao ◽  
N Venkaiah
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Process Parameters ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Recast Layer ◽  
Machining Process ◽  
Micro Hardness ◽  
Recast Layer Thickness ◽  
Inconel 690

Nickel-based alloys are finding a wide range of applications due to their superior properties of maintaining hardness at elevated temperatures, low thermal conductivity and resistance to corrosion. These materials are used in aircraft, power-generation turbines, rocket engines, automobiles, nuclear power and chemical processing plants. Machining of such alloys is difficult using conventional processes. Wire-cut electrical discharge machining is one of the advanced machining processes, which can cut any electrically conductive material irrespective of its hardness. One of the major disadvantages of this process is formation of recast layer as it affects the properties of the machined surfaces. In this study, experimental investigation has been carried out to study the effect of wire-cut electrical discharge machining process parameters on micro-hardness, surface roughness and recast layer while machining Inconel-690 material. Interestingly, hardness of the machined surface was found to be lower than that of the bulk material. The micro-hardness and recast layer thickness are inversely related to the variation of process parameters. Recast layer thickness, surface roughness and hardness of the wire-cut electrical discharge machined surfaces of Inconel-690 are found to be in the range of 10–50 µm, 0.276–3.253 µm and 122–171 HV, respectively, for different conditions. The research findings and the data generated for the first time on hardness and recast layer thickness for Inconel-690 will be useful to the industry.

Improvement in Tensile Strength of FDM Built Parts by Parametric Control

2014 ◽  
Vol 592-594 ◽  
pp. 1075-1079 ◽  
Author(s):  
Swayam Bikash Mishra ◽  
Siba Sankar Mahapatra
Keyword(s):  
Tensile Strength ◽  
Process Parameters ◽  
Fused Deposition Modeling ◽  
Optimal Parameter ◽  
Layer By Layer ◽  
3D Objects ◽  
Fused Deposition ◽  
Solid Models ◽  
Raster Angle ◽  
Deposition Modeling

Fused Deposition Modeling (FDM) is one of the efficient rapid prototyping (RP) technologies that forms 3D objects by adding material layer by layer from CAD generated solid models. However, the FDM built part is hardly anisotropic in nature due to layer-by-layer build mechanism. Literature suggests that mechanical property, especially tensile strength, of FDM built part is severely affected by process parameters. Among all the parameters, contour number happens to be an important parameter because it reduces stress concentration resulting in avoidance of premature breakdown. Therefore, in this work contour number along with five important process parameters such as layer thickness, raster width, part orientation, raster angle and air gap are considered and their effect on tensile strength of FDM built parts is studied. Experiments are conducted using Face Centred Central Composite Design (FCCCD) in order to reduce the experimental runs. An optimal parameter setting has been suggested for the maximisation of tensile strength of the FDM built parts.

scholarly journals Influence of Process Parameters on Tensile Strength of Additive Manufactured PLA Parts using Taguchi Method

2019 ◽  
Vol 8 (3) ◽  
pp. 7635-7639
Keyword(s):  
Tensile Strength ◽  
Layer Thickness ◽  
Fused Deposition Modeling ◽  
Optimal Parameter ◽  
Fused Filament Fabrication ◽  
Influence Of Process Parameters ◽  
Layer Height ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Nozzle Temperature

Influence of layer thickness nozzle temperature and angle on tensile strength of PLA fabricated with FDM (FFF) was experimentally investigated. Polylactic Acid (PLA) is a semi-crystalline and bio-friendly thermoplastic polymer has identified as important material in different applications due to its mechanical characteristics. Fused Deposition Modeling (FDM) is a one of the proved technology in Fused Filament Fabrication (FFF) technique in additive manufacturing process. In present investigation different specimens were fabricated using FDM technique with different layer height and different layer angles for finding influence of these manufacturing parameters on tensile strength of the specimen. Specimens were fabricated and tested as per ASTM D638 standard. It is clearly observed that tensile strength is more for +450 /-450 layer angle than the +00 /-0 0 layer angle for a given layer height(h=0.10 mm, h=0.15mm and h=0.20mm).The TAGUCHI analysis is carried with nozzle temperature, layer thickness and angle finding optimal values. It has been observed that, the optimal parameter is angle, which is equal to 30 0 .the ANOVA variation of angle layer with tensile strength has been observed that 18.10-31.90.

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