scholarly journals Effects of CNC Machining on Surface Roughness in Fused Deposition Modelling (FDM) Products

Materials ◽  
2020 ◽  
Vol 13 (11) ◽  
pp. 2608 ◽  
Author(s):  
Mohammadreza Lalegani Dezaki ◽  
Mohd Khairol Anuar Mohd Ariffin ◽  
Mohd Idris Shah Ismail
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
High Surface ◽  
Great Influence ◽  
Cnc Machining ◽  
Numerical Control ◽  
Fused Deposition Modelling ◽  
High Surface Quality ◽  
Complex Products ◽  
Fused Deposition

Fused deposition modelling (FDM) opens new ways across the industries and helps to produce complex products, yielding a prototype or finished product. However, it should be noted that the final products need high surface quality due to their better mechanical properties. The main purpose of this research was to determine the influence of computer numerical control (CNC) machining on the surface quality and identify the average surface roughness (Ra) and average peak to valley height (Rz) when the specimens were printed and machined in various build orientations. In this study, the study samples were printed and machined to investigate the effects of machining on FDM products and generate a surface comparison between the two processes. In particular, the block and complex specimens were printed in different build orientations, whereby other parameters were kept constant to understand the effects of orientation on surface smoothness. As a result, wide-ranging values of Ra and Rz were found in both processes for each profile due to their different features. The Ra values for the block samples, printed samples, and machined samples were 21, 91, and 52, respectively, whereas the Rz values were identical to Ra values in all samples. These results indicated that the horizontal surface roughness yielded the best quality compared to the perpendicular and vertical specimens. Moreover, machining was found to show a great influence on thermoplastics in which the surfaces became smooth in the machined samples. In brief, this research showed that build orientation had a great effect on the surface texture for both processes.

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 Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

scholarly journals Effects of Electrolyte Flushing and Surface State on Electropolishing TB2 Titanium Alloy

2021 ◽  
Author(s):  
Ying Wei ◽  
Xiaolong Fang ◽  
Ningsong Qu ◽  
Di Zhu
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Quality ◽  
Flow Rate ◽  
High Surface ◽  
Processing Parameters ◽  
Process Time ◽  
High Surface Quality ◽  
Metal Plates ◽  
The Ideal

Abstract TB2 titanium alloys are widely used in the aerospace industry. A high surface quality is required for the performance and fatigue life of titanium alloy parts. Electropolishing is useful for thin metal plates owing to its good processability and conformability. In this study, electrolyte flushing was proposed for electropolishing a large surface and a NaCl-containing ethylene glycol electrolyte was adopted. Three different mechanical grindings were employed for pretreatment, and the ideal surface quality was obtained with a rubber grinding head. Therefore, in the process of electropolishing a large surface, electrolyte flushing is superior to stirring because its flow field is even and controllable. The effects of the main processing parameters (voltage, flow rate, and process time) on the surface roughness and morphology were studied. Finally, a mirror-like surface with a surface roughness of 10.5 nm was obtained after flushing electropolishing for 30 min under a voltage of 25 V and a flow rate of 0.84 m/s.

scholarly journals Mechanical Characterization and Thermodynamic Analysis of Laser-Polished Landscape Design Products Using 3D Printing

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2601
Author(s):  
Yue Ba ◽  
Yu Wen ◽  
Shibin Wu
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
High Surface ◽  
Landscape Design ◽  
Laser Polishing ◽  
Fused Deposition ◽  
Design Structure ◽  
3D Printed ◽  
Stability And Accuracy

Recent innovations in 3D printing technologies and processes have influenced how landscape products are designed, built, and developed. In landscape architecture, reduced-size models are 3D-printed to replicate full-size structures. However, high surface roughness usually occurs on the surfaces of such 3D-printed components, which requires additional post-treatment. In this work, we develop a new type of landscape design structure based on the fused deposition modeling (FDM) technique and present a laser polishing method for FDM-fabricated polylactic acid (PLA) mechanical components, whereby the surface roughness of the laser-polished surfaces is reduced from over Ra 15 µm to less than 0.25 µm. The detailed results of thermodynamics and microstructure evolution are further analyzed during laser polishing. The stability and accuracy of the results are evaluated based on the standard deviation. Additionally, the superior tensile and flexural properties are examined in the laser-polished layer, in which the ultimate tensile strength (UTS) is increased by up to 46.6% and the flexural strength is increased by up to 74.5% compared with the as-fabricated components. Finally, a real polished landscape model is simulated and optimized using a series of scales.

scholarly journals Experimental investigation of the machining characteristics in diamond wire sawing of unidirectional CFRP

2021 ◽  
Author(s):  
Lukas Seeholzer ◽  
Stefan Süssmaier ◽  
Fabian Kneubühler ◽  
Konrad Wegener
Keyword(s):  
Surface Quality ◽  
Influencing Factors ◽  
Material Properties ◽  
High Surface ◽  
Workpiece Surface ◽  
High Surface Quality ◽  
High Productivity ◽  
Surface Temperatures ◽  
Process Forces ◽  
The Wire

AbstractEspecially for slicing hard and brittle materials, wire sawing with electroplated diamond wires is widely used since it combines a high surface quality with a minimum kerf loss. Furthermore, it allows a high productivity by machining multiple workpieces simultaneously. During the machining operation, the wire/workpiece interaction and thus the material removal conditions with the resulting workpiece quality are determined by the material properties and the process and tool parameters. However, applied to machining of carbon fibre reinforced polymers (CFRP), the process complexity potentially increases due to the anisotropic material properties, the elastic spring back potential of the material, and the distinct mechanical wear due to the highly abrasive carbon fibres. Therefore, this experimental study analyses different combinations of influencing factors with respect to process forces, workpiece surface temperatures at the wire entrance, and the surface quality in wire sawing unidirectional CFRP material. As main influencing factors, the cutting and feed speeds, the density of diamond grains on the wire, the workpiece thickness, and the fibre orientation of the CFRP material are analysed and discussed. For the tested parameter settings, it is found that while the influence of the grain density is negligible, workpiece thickness, cutting and feed speeds affect the process substantially. In addition, higher process forces and workpiece surface temperatures do not necessarily deteriorate the surface quality.

Variothermal Foam Injection Molding - Dimensional Stability with High Surface Quality

2017 ◽  
Vol 36 (3) ◽  
pp. 151-166 ◽  
Author(s):  
Christian Hopmann ◽  
Nicolai Lammert ◽  
Yuxiao Zhang
Keyword(s):  
Surface Quality ◽  
Surface Defects ◽  
Control Strategies ◽  
High Surface ◽  
Skin Layer ◽  
High Surface Quality ◽  
Major Disadvantage ◽  
Scope Of Application ◽  
Specific Material ◽  
Foam Injection Molding

Thermoplastic foam injection moulding offers various advantages for both processing and product design. Despite its many benefits, the moderate surface quality still constitutes a major disadvantage of this process. The mould temperature can be controlled dynamically to improve the surface quality. Different dynamic temperature control strategies are employed and analysed regarding their effectiveness and scope of application. Mould temperatures above the specific material transition temperatures allow the surface defects to be cured and enable the production of foamed thermoplastic parts with surface qualities comparable to those of the compact reference samples. The high mould temperatures during the injection phase alter the foam structure and the skin layer thicknesses, which impacts the mechanical properties.

scholarly journals Electropolishing Parametric Optimization of Surface Quality for the Fabrication of a Titanium Microchannel Using the Taguchi Method

Machines ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 325
Author(s):  
Muslim Mahardika ◽  
Martin Andre Setyawan ◽  
Tutik Sriani ◽  
Norihisa Miki ◽  
Gunawan Setia Prihandana
Keyword(s):  
Taguchi Method ◽  
Surface Quality ◽  
Process Parameters ◽  
Applied Voltage ◽  
High Surface ◽  
Machining Process ◽  
Machining Parameters ◽  
Pareto Analysis ◽  
High Surface Quality

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L9 orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

Influence of Manufacturing Process on the Fatigue Strength of Gears

2014 ◽  
Vol 1018 ◽  
pp. 269-276
Author(s):  
Andrea Reiß ◽  
Ulf Engel
Keyword(s):  
Fatigue Strength ◽  
Surface Quality ◽  
Fatigue Behavior ◽  
High Surface ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Cold Forging ◽  
Hardness Distribution ◽  
Forming Process ◽  
High Surface Quality

With cold forging processes it is possible to produce parts characterized by high strength, high dimensional accuracy and high surface quality. In order to optimize the forming process and to be able to use the advantages of cold forging specifically and combined, it is necessary to find correlations between manufacturing parameters on the one side, strength and other properties like hardness distribution and surface quality of the component on the other side. The research work covered in this paper focuses on the correlation of the components properties influenced by its manufacturing history and their fatigue strength. The used component is a gear produced by a lateral cold forging process. For the investigations an experimental setup has been designed. The aim for the design of the setup is to reproduce the real contact condition for the contact of two gears. To obtain different component properties the production process of the gear was varied by producing the parts by a milling operation. First of all, the components’ properties, for example hardness distribution, remaining residual stresses, orientation of fibers and surface quality, were determined. The components’ fatigue behavior was determined using a high frequency pulsator and evaluated in terms of finite life fatigue strength and fatigue endurance limit. These examinations were used to produce Woehler curves for the differently manufactured components with a certain statistical data analysis method.

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