experimentation on fused deposition modelling process · raster width along with their interactions...

EXPERIMENTATION ON FUSED DEPOSITION

MODELLING PROCESS

Priyanshu S. Prajapati*

ME Student, Department of Mechanical Engineering, Sardar Vallabhbhai Patel Institute of

Technology, Vasad, Gujarat, India

ABSTRACT:

Fused modelling process is highly efficient rapid prototyping approach that’s makes it possible

to rapidly generate even a much complicated parts. This paper presents effect of deviation

control parameter step-size of Creo modelling software on surface roughness, dimensional

Accuracy, circularity and compression strength of ASTM standard test specimens modelled by

FDM process from 3D printer from ABS material. Effect of deviation control parameter step

size on surface roughness , circularity at horizontal , vertical and 45 degree print orientation.

Effect of slicing parameter on surface roughness and circularity is also measure. As step size

increases surface roughness increases and circularity decreases. Horizontal print orientation

gives better surface finish whereas vertical print orientation gives better circularity.

KEYWORDS : FDM, ABS, Step-size, Circularity

INTRODUCTION

Fused deposition modeling process of rapid prototyping of additive manufacturing

brach.various process parameters like orientation, object fill, print orientation, extruder

temprature, travel speed, extrusion temprature, layer thickness, plateform temprature, no of

shells etc. Materials use for the process are ultem, abs, pla etc.the effect of above process

parameters are analyse on the different materials, surface roughness, mechanical properties,

dimentional, and geometrical characterstics are evaluate in this study.different apporoches like

novel,taghuchi ,design of exprements, anova , fea anlysis are use for the obtimization of the

above process parameters.differents tests are shows the mechanical behaviour of fdm produces

parts for the differents materials and thair comparision. the effect of deviation control

parameter stepsize on surface roughness, circularity at horizontal , vertical and 45o print

orientation. Effect of slicing parameter on surface roughness and

circularity is also measure. As stepsize increses surface roughness increses and circularity

decreses.horizontal print orientation gives better surface finish where as vertical print

orientation gives better circularity.

LITRATURE REVIEW

Dario Croccoloet .et .al[1]

The Fused Deposition Modelling process is a highly efficient Rapid

Prototyping approach that makes it possible to rapidly generate even much complicated parts.

Unfortunately, the Fused Deposition Modelling is affected by several parameters, whose

setting may have a strong impact on the components strength. This paper is devoted to the

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (4), April, 2017

IJSRE Vol. 1 (4), April, 2017 www.ijsre.in 18

study of the effects generated by the Fused Deposition Modelling production parameters on the

tensile strength and on the stiffness of the generated components, tackling the question from

both the experimental and the numerical points of view. For this purpose, an analytical model

was developed, which is able to predict the strength and the stiffness properties, based on the

number of contours deposited around the component edge and on the setting of the other main

parameters of the deposition process. The fundamental result of the paper consists in the

possibility of predicting the mechanical behaviour of the Fused Deposition modelled parts,

once the raster pattern (dimensions, number of contours, raster angle) has been stated. The

effectiveness of the theoretical model has been verified by comparison to a significant number

of experimental results, with mean errors of about 4%.

Anoop K. Sood .et .al [2]

Fused deposition modelling (FDM) is gaining distinct advantage in

manufacturing industries because of its ability to manufacture parts with complex shapes

without any tooling requirement and human interface. The properties of FDM built parts

exhibit high dependence on process parameters and can be improved by setting parameters at

suitable levels. Anisotropic and brittle nature of build part makes it important to study the

effect of process parameters to the resistance to compressive loading for enhancing service life

of functional parts. Hence, the present work focuses on extensive study to understand the effect

of five important parameters such as layer thickness, part build orientation, raster angle, raster

width and air gap on the compressive stress of test specimen. The study not only provides

insight into complex dependency of compressive stress on process parameters but also

develops a statistically validated predictive equation. The equation is used to find optimal

parameter setting through quantum-behaved particle swarm optimization (QPSO). As FDM

process is a highly complex one and process parameters influence the responses in a non-linear

manner, compressive stress is predicted using artificial neural network (ANN) and is compared

with predictive equation.

Anoop Kumar Sood .et .al[3]

This paper presents experimental investigations on influence of

important process parameters viz., layer thickness, part orientation, raster angle, air gap and

raster width along with their interactions on dimensional accuracy of Fused Deposition

Modelling (FDM) processed ABSP400 (acrylonitrile-butadine-styrene) part. It is observed that

shrinkage is dominant along length and width direction of built part. But, positive deviation

from the required value is observed in the thickness direction. Optimum parameters setting to

minimize percentage change in length, width and thickness of standard test specimen have

been found out using Taguchi’s parameter design. Experimental results indicate that optimal

factor settings for each performance characteristic are different. Therefore, all the three

responses are expressed in a single response called grey relational grade. Finally, grey Taguchi

method is adopted to obtain optimum level of process parameters to minimize percentage

change in length, width and thickness simultaneously. The FDM process is highly complex one

and hardly any theoretical model exist for the prediction purpose. The process parameters

influence the responses in a highly non-linear manner. Therefore, prediction of overall

dimensional accuracy is made based on artificial neural network (ANN).


IJSRE Vol. 1 (4), April, 2017 www.ijsre.in Page 119

Vijay.B.Nidagundi .et .al [4]

This paper discusses optimization studies on process parameters

for fused deposition modelling (fdm). Layer thickness, Orientation angle and fill angle are the

process variables considered for optimization. Ultimate tensile strength, surface roughness,

Dimensional accuracy and manufacturing time were considered as response parameters.

Experiments were designed using well Known taguchi’s l9 orthogonal array, taguchi’s s/n ratio

was used to identify optimum parameter values. Effectiveness of each Parameter was

investigated using analysis of variance. Furthur, performance of optimum conditions were

validated by conducting Verification experiment.

L.M. Galantucci .et .al [5]

Fused deposition modeling (FDM) is an additive technology that

suffers badly from low surface quality, Requiring hand finishing for even the most basic levels

of part quality. In this paper the authors study the influence of fdmmachining parameters on

acrylonitrile butadiene Styrene (ABS) prototypes surface finish. The surface finish of products

after the modification of extrusion Parameters has been measured and processed through

designed experiments. The chemical posttreatment Does not require human intervention and

has led to a significant improvement in surface finish At the expense of a negligible change in

the prototype size.

Miquel Domingo-Espin .et .al[6]

Building end-use functional parts with additive

manufacturing (AM) technologies is a challenging task. Several factors influence their surface

finish, dimensional accuracy, mechanical properties and cost. Their orientation inside the

building chamber is one of the most significant factors in AM processes. When using Fused

Deposition Modeling (FDM) to build such parts, additional factors must be considered. This

paper aims to accomplish two purposes: finding a good model to simulate FDM parts and

correlating a finite element analysis (FEA) simulation with physical testing. The first objective

was achieved by experimental tensile test of specimens to determine the nine mechanical

constants that defines the stiffness matrix of an orthotropic material. Three Young’s modulus,

three Poisson’s ratio and three shear modulus were experimentally obtained as well as yield

tensile and ultimate strength of each specimen. A simple part was designed and manufactured

in different orientations to be physically tested and simulated to achieve the second objective.

Polycarbonate (PC) was used as part material. Combined loading including bending and

torsion was used. Differences on mechanical response were observed during the physical test

of the parts depending on the building direction. Conclusions comment results and the

convenience of using a different constitutive model depending on the design and use

specifications.

Mostafa Nikzad .at .el [7]

Fused deposition modelling (FDM) is a filament based rapid

prototyping system which offers the possibility of introducing new composite material for the

FDM process as long as the new material can be made in feedstock filament form. Swinburne

has been undertaking extensive research in development of new composite materials involving

acrylonitrile-butadiene-styrene (ABS) and other materials including metals. In order to predict

the behaviour of new ABS based composite materials in the course of FDM process, it is

necessary to investigate the flow of the composite material in liquefier head. No such study is



available considering the geometry of the liquefier head. This paper presents 2-D and 3-D

numerical analysis of melt flow behaviour of a representative ABS-iron composite through the

90-degree bent tube of the liquefier head of the fused deposition modelling process using

ANSYS FLOTRAN and CFX finite element packages. Main flow parameters including

temperature, velocity, and pressure drop have been investigated. Filaments of the filled ABS

have been fabricated and characterized to verify the possibility of prototyping using the new

material on the current FDM machine. Results provide promising information in developing

the melt flow modelling of metal-plastic composites and in optimising the FDM parameters for

better part quality with such composites.

Michael Dawoud .et .al [8]

Fused deposition modelling (FDM) in contrast to injection

moulding was studied to investigate the effect of processing technique on the mechanical

behaviour of virgin ABS. FDM parameters were further altered in terms of varying raster angle

and gap to further explore the potential of this technique. Results show that an adequate

selection of FDM parameters is able to reach mechanical properties comparable to those of

injection moulded parts in both static and dynamic loading modes. Here, a negative raster gap

proved to be most significant in enhancing mechanical behaviour. A raster angle layup of

−45◦/+45◦ proves to offer maximum tensile and impact strength, whereas highest flexural

strength was recorded for a 0/90◦ scaffolding system. In contrast, a positive gap drastically

reduces the performance. Dimensional analysis further show no significant alterations of

dimensions are to be expected with varying raster angle and gap.

L. M. Galantucci .et .al [9]

In this paper an analytical dimensional performance evaluation and

comparison is illustrated, done on benchmarks manufactured Using two different 3D FDM

printers: an industrial system, and an open-source one (a modified Fab@Home Model 1

printer). Using a factorial analysis design of experiment (DOE), optimum process parameters

were found to improve dimensional accuracy On rectangular test specimens, minimizing

changes in length, width and height. Fab@Home printer demonstrated to be a good Platform,

simple, flexible and inexpensive.

H. Louche .et .al [10]

An experimental and modeling study of the thermomechanical behavior

of an ABS polymer structural Component during an impact test is presented. The structural

component was a heel of a woman’s shoe Made of ABS polymer material reinforced or not by

a pin. Kinematics and thermal full field measurement Techniques were used to observe the

material and structural component during preliminary experimental Tensile and impact tests.

With the kinematic fields it was possible to identify the stress–strain Response, which takes the

necking localization into account. Positive volume variations were also Observed during these

tensile tests, which were associated with the crazing damage mechanisms in this Type of

polymer. The thermal fields measured during these tests showed high temperature variations (a

few K to 25 K) in the zone where strain was localized. The associated thermal softening,

estimated by the stress–strain responses at various imposed room Temperatures, was taken into

account in the Johnson Cook material model. This model was selected Because it can easily

include the strain, strain rates and temperature effects. A thermomechanical Simulation was



built. This weak coupled model is based on the assumption of both the adiabaticity of the

Problem and a fixed ratio (90%) of the local volume plastic power of the heat sources. The

finite element model was restricted to the first impact test. A specific instrumentation of the

Machine was performed to validate the model. Displacements, linear and angular velocities

and impact Load were measured. In addition to these local data, kinematics and thermal full

field measurements Were proposed and provided a rich spatiotemporal database to compare the

experimental and numerical Results. A qualitative agreement for the strain distribution and an

under-estimation of about 20% of the Impact load was finally obtained by the model.

Omar Ahmed Mohamed .et .al [11]

Fused deposition modeling (FDM) is one of the widely

used additive manufacturing technologies Because it has flexibility and ability to build

complex parts. The accuracy of parts Fabricated by FDM is greatly influenced by various

process parameters. FDM process has a Complex mechanism in building parts and often poses

difficulty in understanding adequately How conflicting FDM parameters will determine part

quality and accuracy. Sectors such as medical implant, telecommunication, electronics and

aerospace require Increasingly higher levels of dimensional accuracy. Thus, traditional

methods of ensuring Quality do not effectively address global markets and customer’s needs.

This study proposes An I-optimality criterion for the optimization of FDM process parameters

in order To address the limitations of the commonly used traditional designs. This study also

aims To develop mathematical models in order to establish nonlinear relationship between

process Parameters and dimensional accuracy. The results show that I-optimality criterion is

Very promising technique in FDM process parameter optimization. Confirmation experiments

Show that the proposed method has great advantages in the aspect of both accuracy And

efficiency compared with traditional methods proposed in previous studies.

Anoop Kumar Sood .et .al[12]

Fused deposition modelling (FDM) is a fast growing rapid

prototyping (RP) technology due to its ability to Build functional parts having complex

geometrical shape in reasonable time period. The quality of built Parts depends on many

process variables. In this study, five important process parameters such as layer Thickness,

orientation, raster angle, raster width and air gap are considered. Their influence on three

Responses such as tensile, flexural and impact strength of test specimen is studied.

Experiments are Conducted based on central composite design (CCD) in order to reduce

experimental runs. Empirical Models relating response and process parameters are developed.

The validity of the models is testedUsing analysis of variance (ANOVA). Response surface

plots for each response is analysed and optimal Parameter setting for each response is

determined. The major reason for weak strength may be attributed To distortion within or

between the layers. Finally, concept of desirability function is used for maximizing All

responses simultaneously.

Manu Srivastava .et .al [13]

Functionally graded materials (FGM) which are also called tailor

made materials, are composites with continuously varying mechanical properties. The

limitations on the component materials available for specific RP processes calls for the

development of tailor made material properties in the available material options. This paper



proposes a technique to develop and fabricate FGM using Fused Deposition Modelling (FDM)

technique. An attempt is made to relate the FDM process parameters with the material

properties for the given ABS material. These relations are used to assign tailor made properties

to the component in various regions. By actual CAD modeling and analysis using ANSYS 14,

it is established that the deformation due to given load is considerably reduced for the

component made by assigning unique set of parameters in a customized fashion.

J Sudeepan .et .al[14]

The tribological properties of acrylonitrile-butadiene-styrene (ABS)

polymer filled with micron-sized calcium carbonate (CaCO3) are studied in this paper. Filler

content, normal load and sliding speed are considered as design parameters and coefficient of

friction (COF) and specific wear rate are considered as the responses. The experiments are

conducted on multi-tribotester (blockon- roller configuration) based on L27 orthogonal array

(OA). The optimum design parameter combination for minimum coefficient of friction and

specific wear rate are found using grey relational analysis. The optimum parameter

combination is found to be 5% of filler content, 35 N of load and 120 rpm of speed. Analysis

of variance (ANOVA) is also used to find out the most influential factor which affects the

tribological properties. The most influential factor is normal load followed by sliding speed

and filler content. Further, a confirmation test is carried out to validate the result and it is seen

that the grey relational grade is increased about 72.56% from the initial to the optimum

condition. Finally, surface morphology is studied using scanning electron microscopy (SEM).

P.J. Nuñez .et .al [15]

Fused Deposition Modelling (FDM) has become extensively used for

low-cost printers. Normally, commercial manufacturers of printers only provide information on

layer thickness, but no information is given as to dimensional accuracy, and the surface

characteristics obtained in manufactured components. The aim of this study was to determine

the dimensional accuracy, flatness, and surface texture obtained in FDM rapid prototype with

ABS-plus as the model material. In the experimental test, two densities (low, solid) and two

layer thicknesses (0.178 mm, 0.254 mm) were used. The best dimensional behaviour was

obtained with the configuration of maximum layer thickness (0.254 mm) and solid density

(100%) with a The best finish surface and minimum flatness error were obtained with less

layer thickness (0.178 mm) and solid density (100%). This study has established the optimum

configurations for the manufacture of components with FDM 3D printing and ABS-plus.

CONCLUSIONS

We know about the standard test that can be perform on the material and know about

strength and weakness of the material and the different process and methodology that can be

perform so that the the require strength can we get to be in the desire manner to perform the

material s function satisfactorily.

We can know about the different approaches and methods to evaluate the response of

parameters and the levels of the parameters and deciding the control methods for the same.

The effect of the parameters on surface roughness, dimensional characteristics, geometrical



characteristics, mechanical properties and some other parameters.

Study includes FDM process parameters like object infill (%),print location, extruder

temperature, print orientation, travel speed, extrusion speed, plate form temp, layer

thickness ,no of shells, Infill density, infill pattern, infill shell spacing, feed rate.

Novel, Taguchi, design of experiment, Anova, FEA analysis are various approaches utilise

for mechanical characterization of FDM parts.

Also the effects of above process parameters give us effect on the mechanical properties,

surface roughness, dimensional and geometrical characteristics.

As step size increases deviation control parameter chord angle, chord height and step size

increases meshing size of tessellated triangles.

Surface roughness Raavg, Rqavg and Ryavg = Raavg values increses with increases in step

size.

Order of surface roughness for print orientation is as below:

Horizontal < vertical < 45 degree

As step size increases, value of circularity decreases.

Order of circularity for given print orientation is as below :

Vertical < horizontal <45 degree

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