Abrasive flow finishing of FDM printed parts using a sustainable media

Abstract

Purpose The purpose of this paper is to study the integration between fused deposition modeling (FDM) technology and abrasive flow machining process to improve the surface quality of FDM printed parts. FDM process has some limitations in terms of accuracy and surface finish. Hence, post-processing operations are essential to increase the quality of the part. Design/methodology/approach Initially, a sustainable polymer abrasive gel-based media (SPAGM) using natural polymer and natural additives (waste vegetable oil) was prepared using different combinations of (abrasive mesh size, percentage of abrasives and percentage of liquid synthesizer); then the characterization of media was done to check various properties. As media is an essential part in the process which helps in increase the surface finish, it needs to have some desired characteristics such as the following: the developed SPAG needs to hold the abrasives; its viscosity has to be medium so that it can easily flow through the machine; and its thermal stability caused by the increase in the temperature during various cycles of operation. For that, it is characterized rheologically as well as thermally to find its various properties. Findings Experiments were performed on FDM-printed parts using an L9 orthogonal array with different parameters to find their effect on the workpiece. Scanning electron microscope images of SGAPM showed sharp edges of abrasive particles and bonding pattern between polymer chain molecules. Good surface finish and material removal rate (MRR) was observed at high pressure and long finishing time with 50 per cent abrasive concentration. Originality/value The authors confirm that this work is original and has neither been published elsewhere nor is it currently under consideration for publication elsewhere.

State of art review on sustainable additive manufacturing

“…Mali et al (2018) studied and analyzed significant factors affecting the surface finish of 3D printed parts. They used unidirectional abrasive flow machining to enhance the surface finish of 3D printed parts.…”

Application of total interpretive structural modelling (TISM) for analysis of factors influencing sustainable additive manufacturing: a case study

“…They concluded that AM process is more sustainable when weight reduction is more than 50 per cent and when use phase is also included in assessment. Mali et al (2018) examined the factors affecting the surface finish of AM printed parts. They used analysis of variance for analyzing the influence of factors on surface finish.…”

A finishing process via ultrasonic drilling for additively manufactured carbon fiber composites

“…In addition, it does not require clamping of the part and the outcome is less sensitive to FDM parameters. Abrasive flow machining was used to remove the material, in micro/nano level, from the 3D printed objects and smoothen the surface with no effect on the mechanical properties (Mali et al, 2018). Another nanofinishing approach using ball end magnetorheological process could reduce the surface roughness of PLA part from 20 mm to 81 nm.…”