scholarly journals Effect of Ultrasonic Vibration on Interlayer Adhesion in Fused Filament Fabrication 3D Printed ABS

Polymers ◽  
2019 ◽  
Vol 11 (2) ◽  
pp. 315 ◽  
Author(s):  
Alireza Tofangchi ◽  
Pu Han ◽  
Julio Izquierdo ◽  
Adithya Iyengar ◽  
Keng Hsu
Keyword(s):  
Ultrasonic Vibration ◽  
Physical Phenomenon ◽  
Thermal Conditions ◽  
Acrylonitrile Butadiene Styrene ◽  
Polymer Chains ◽  
Fused Filament Fabrication ◽  
Property Anisotropy ◽  
History Of ◽  
3D Printed ◽  
Mechanical Property Anisotropy

One of the fundamental issues in the Fused Filament Fabrication (FFF) additive manufacturing process lies in the mechanical property anisotropy where the strength of the FFF-3D printed part in the build-direction can be significantly lower than that in other directions. The physical phenomenon that governs this issue is the coupled effect of macroscopic thermal mechanical issues associated with the thermal history of the interface, and the microscopic effect of the polymer microstructure and mass transfer across interfaces. In this study it was found that the use of 34.4 kHz ultrasonic vibrations during FFF-3D printing results in an increase of up to 10% in the interlayer adhesion in Acrylonitrile Butadiene Styrene (ABS), comparing the printing in identical thermal conditions to that in conventional FFF printing. This increase in the interlayer adhesion strength is attributed to the increase in polymer reptation due to ultrasonic vibration-induced relaxation of the polymer chains from secondary interactions in the interface regions.

scholarly journals Essential work of fracture assessment of acrylonitrile butadiene styrene (ABS) processed via fused filament fabrication additive manufacturing

2021 ◽  
Author(s):  
Pawan Verma ◽  
Jabir Ubaid ◽  
Andreas Schiffer ◽  
Atul Jain ◽  
Emilio Martínez-Pañeda ◽  
...  
Keyword(s):  
Acrylonitrile Butadiene Styrene ◽  
Essential Work ◽  
Fused Filament Fabrication ◽  
Essential Work Of Fracture ◽  
Fracture Properties ◽  
Raster Angle ◽  
3D Printed ◽  
Printing Direction ◽  
Work Of Fracture ◽  
Butadiene Styrene

AbstractExperiments and finite element (FE) calculations were performed to study the raster angle–dependent fracture behaviour of acrylonitrile butadiene styrene (ABS) thermoplastic processed via fused filament fabrication (FFF) additive manufacturing (AM). The fracture properties of 3D-printed ABS were characterized based on the concept of essential work of fracture (EWF), utilizing double-edge-notched tension (DENT) specimens considering rectilinear infill patterns with different raster angles (0°, 90° and + 45/− 45°). The measurements showed that the resistance to fracture initiation of 3D-printed ABS specimens is substantially higher for the printing direction perpendicular to the crack plane (0° raster angle) as compared to that of the samples wherein the printing direction is parallel to the crack (90° raster angle), reporting EWF values of 7.24 kJ m−2 and 3.61 kJ m−2, respectively. A relatively high EWF value was also reported for the specimens with + 45/− 45° raster angle (7.40 kJ m−2). Strain field analysis performed via digital image correlation showed that connected plastic zones existed in the ligaments of the DENT specimens prior to the onset of fracture, and this was corroborated by SEM fractography which showed that fracture proceeded by a ductile mechanism involving void growth and coalescence followed by drawing and ductile tearing of fibrils. It was further shown that the raster angle–dependent strength and fracture properties of 3D-printed ABS can be predicted with an acceptable accuracy by a relatively simple FE model considering the anisotropic elasticity and failure properties of FFF specimens. The findings of this study offer guidelines for fracture-resistant design of AM-enabled thermoplastics. Graphical abstract

Predicting strength of additively manufactured thermoplastic polymer parts produced using material extrusion

2018 ◽  
Vol 24 (2) ◽  
pp. 321-332 ◽  
Author(s):  
Joseph Bartolai ◽  
Timothy W. Simpson ◽  
Renxuan Xie
Keyword(s):  
Infrared Imaging ◽  
Acrylonitrile Butadiene Styrene ◽  
Temperature History ◽  
Interface Temperature ◽  
Fused Filament Fabrication ◽  
Content Type ◽  
Material Extrusion ◽  
Rheological Data ◽  
History Of ◽  
Butadiene Styrene

Purpose The weakest point in additively manufactured polymer parts produced by material extrusion additive manufacturing (MEAM) is the interface between adjacent layers and deposition toolpaths or “roads”. This study aims to predict the mechanical strength of parts by utilizing a novel analytical approach. Strength predictions are made using the temperature history of these interfaces, polymer rheological data, and polymer weld theory. Design/methodology/approach The approach is validated using experimental data for two common 3D-printed polymers: polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). Interface temperature history data are collected in situ using infrared imaging. Rheological data of the polycarbonate and acrylonitrile butadiene styrene used to fabricate the fused filament fabrication parts in this study have been determined experimentally. Findings The strength of the interfaces has been predicted, to within 10% of experimental strength, using polymer weld theory from the literature adapted to the specific properties of the polycarbonate and acrylonitrile butadiene styrene feedstock used in this study. Originality/value This paper introduces a novel approach for predicting the strength of parts produced by MEAM based on the strength of interfaces using polymer weld theory, polymer rheology, temperature history of the interface and the forces applied to the interface. Unlike methods that require experimental strength data as a prediction input, the proposed approach is material and build orientation agnostic once fundamental parameters related to material composition have been determined.

Synergistic effect of loads and speeds on the dry sliding behaviour of fused filament fabrication 3D-printed acrylonitrile butadiene styrene pins with different internal geometries

2020 ◽  
Vol 108 (7-8) ◽  
pp. 2525-2539 ◽  
Author(s):  
Mohd Fadzli Bin Abdollah ◽  
Mohamad Nordin Mohamad Norani ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Hilmi Amiruddin ◽  
Faiz Redza Ramli ◽  
...  
Keyword(s):  
Synergistic Effect ◽  
Acrylonitrile Butadiene Styrene ◽  
Dry Sliding ◽  
Fused Filament Fabrication ◽  
3D Printed ◽  
Butadiene Styrene

scholarly journals Essential work of fracture assessment of acrylonitrile butadiene styrene (ABS) processed via fused filament fabrication additive manufacturing

2021 ◽  
Author(s):  
Pawan Verma ◽  
Jabir Ubaid ◽  
Andreas Schiffer ◽  
Atul Jain ◽  
Emilio Martínez Pañeda ◽  
...  
Keyword(s):  
Acrylonitrile Butadiene Styrene ◽  
Essential Work ◽  
Fused Filament Fabrication ◽  
Essential Work Of Fracture ◽  
Fracture Properties ◽  
Raster Angle ◽  
3D Printed ◽  
Printing Direction ◽  
Work Of Fracture ◽  
Butadiene Styrene

Experiments and finite element (FE) calculations were performed to study the raster angle–dependent fracture behaviour of acrylonitrile butadiene styrene (ABS) thermoplastic processed via fused filament fabrication (FFF) additive manufacturing (AM). The fracture properties of 3D-printed ABS were characterized based on the concept of essential work of fracture (EWF), utilizing double-edge-notched tension (DENT) specimens considering rectilinear infill patterns with different raster angles (0°, 90° and + 45/− 45°). The measurements showed that the resistance to fracture initiation of 3D-printed ABS specimens is substantially higher for the printing direction perpendicular to the crack plane (0° raster angle) as compared to that of the samples wherein the printing direction is parallel to the crack (90° raster angle), reporting EWF values of 7.24 kJ m−2 and 3.61 kJ m−2, respectively. A relatively high EWF value was also reported for the specimens with + 45/− 45° raster angle (7.40 kJ m−2). Strain field analysis performed via digital image correlation showed that connected plastic zones existed in the ligaments of the DENT specimens prior to the onset of fracture, and this was corroborated by SEM fractography which showed that fracture proceeded by a ductile mechanism involving void growth and coalescence followed by drawing and ductile tearing of fibrils. It was further shown that the raster angle–dependent strength and fracture properties of 3D-printed ABS can be predicted with an acceptable accuracy by a relatively simple FE model considering the anisotropic elasticity and failure properties of FFF specimens. The findings of this study offer guidelines for fracture-resistant design of AM-enabled thermoplastics.

scholarly journals 3D Printed End of Arm Tooling (EOAT) for Robotic Automation

Robotics ◽  
2018 ◽  
Vol 7 (3) ◽  
pp. 49
Author(s):  
Daniel Ong U Jing ◽  
Declan Devine ◽  
John Lyons
Keyword(s):  
Lean Manufacturing ◽  
Low Cost ◽  
Acrylonitrile Butadiene Styrene ◽  
Fused Filament Fabrication ◽  
3D Printed ◽  
Potential Weight ◽  
Materials Used ◽  
Strength And Stiffness ◽  
Flexural Tests ◽  
Robotic Automation

This research furthers the practice of designing and manufacturing End of Arm Tooling (EOAT) by utilizing a low cost additive manufacturing Fused Filament Fabrication (FFF) technique to enable tool weight saving and provision of low cost EOATs on demand, thereby facilitating zero inventory lean manufacturing. The materials used in this research for the fabrication of the EOAT parts were Acrylonitrile butadiene styrene (ABS) and nylon with infill densities of 20% and 100%. Three-point flexural tests were performed to determine the differences in strength and stiffness between varying polymers, infill ratios, and a standard metal part. Additionally, potential weight savings were identified and challenges with utilizing low cost FFF technologies are outlined. A motion of programmed trajectories was executed utilizing a standard 6-axis robot and the power consumption was evaluated. This study demonstrates the utility of using thermoplastic material with the fabrication of 3D printed parts used in EOATs.

Investigation of structure–mechanical property relationship in fused filament fabrication of the polymer composites

2019 ◽  
Vol 2 (2) ◽  
pp. 167-174 ◽  
Author(s):  
Sanjay Kumar ◽  
Pulak Bhushan ◽  
Nishant Sinha ◽  
Om Prakash ◽  
Shantanu Bhattacharya
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Pore Size ◽  
Acrylonitrile Butadiene Styrene ◽  
Neck Length ◽  
Fused Filament Fabrication ◽  
Build Orientation ◽  
Nylon 12 ◽  
3D Printed ◽  
3D Printing Technique

Fused filament fabrication (FFF) process is an emerging 3D printing technique primarily used for rapid prototyping in academic and industrial environments. The mechanical properties of these 3D-printed samples are highly anisotropic in nature and depend on various process parameters. Literature suggests that build orientation is a crucial parameter affecting the mesostructural and mechanical properties of these parts. However, there are no existing models that can correlate the mechanical properties of these printed parts with their mesostructural properties. Herein, a multiparametric mathematical model has been developed, establishing a correlation between the tensile strength, neck length, and pore size of the printed parts. An extensive investigation is carried out on six materials, namely acrylonitrile butadiene styrene (ABSplus P430, ABS POLYLAC® PA-757, and LG ABS RS657), polycarbonate (PC), FDM Nylon 12, and PC-ABS alloys printed in two different build orientations (XZ and ZX). The change in mechanical properties with respect to build orientation and the mesostructural properties was examined. It was established that parts printed in the XZ orientation exhibit a higher tensile strength, owing to the higher neck length and smaller pore size. Regression analysis was carried out to develop mathematical models correlating the tensile strength with the mesostructural properties of the printed parts. A good agreement is observed between the theoretically predicted and experimentally found tensile strength.

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