Effects of milling parameters on roughness and burr formation in 3D- printed PLA components

Mehtedi, Mohamad El; Buonadonna, Pasquale; Carta, Mauro Giovanni; Mohtadi, Rayane El; Marongiu, Gianluca; Loi, Gabriela; Aymerich, Francesco

doi:10.1016/j.procs.2022.12.356

Cited by 11 publications

(17 citation statements)

References 16 publications

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“…Fortunately, post-processing techniques offer avenues to mitigate surface roughness issues. Among these techniques, milling has emerged as a viable option, with previous studies yielding promising results [ 7 , 8 ]. Moreover, employing milling post-processing not only addresses surface roughness concerns but also contributes to enhancing dimensional accuracy.…”

Section: Experimental Design Materials and Methodsmentioning

confidence: 99%

Surface roughness and dimension accuracy data from hybrid manufacturing process using PLA material

Susanto,

Rashyid,

Tanbar

et al. 2024

Data in Brief

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Section: Experimental Design Materials and Methodsmentioning

confidence: 99%

Surface roughness and dimension accuracy data from hybrid manufacturing process using PLA material

Susanto,

Rashyid,

Tanbar

et al. 2024

Data in Brief

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“…Burr height at the edges of milled surfaces was quantified by taking three perpendicular profile measurements spaced 10 mm apart. With the same method used in [47]. These measurements were analyzed in Matlab using the least-squares method to define a baseline using the points without burrs.…”

Section: Methodsmentioning

confidence: 99%

“…FDM-printed material Rotation speed (𝑛) Feed rate (𝑉 ) Pamarac et al [51] ABS 3500 rpm 35 -840 mm/min Pamarac et al [51] PLA 3500 rpm 35 -1880 mm/min Lalelgani et al [46] PLA 3283 -10504 rpm 1000 mm/min El Mehtedi et al [47] PLA 3500-8000 rpm 400-800 mm/min Lalegani Dezaki et al [46] PLA 3500 rpm 1200 mm/min Guo et al [50] PEEK and CF-PEEK 3000-12,500 rpm 0.02-0.1 mm/teeth Cococcetta et al [34] Onyx and CF-Onyx 6000 rpm 600-1200 mm/min Vallejo et al [36] PETG and CF-PETG 3500 rpm 800 mm/min El Mehtedi et al [48,52] PETG and CF-PETG 3500-8000 rpm 400-800 mm/min…”

Section: Authorsmentioning

confidence: 99%

“…Since the above-mentioned issues may question the use of FDM-printed components in critical load-bearing applications, several post-printing approaches have been proposed, encompassing applying post-processing heat treatment [31,32], acetone vapor bath [43,44], hot cutter machining [45], and CNC milling [45][46][47][48]. In particular, the latter has been widely exploited to refine FDMprinted components.…”

Section: Introductionmentioning

confidence: 99%

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Optimizing Milling Parameters for Enhanced Machinability of 3D‐Printed Materials: An Analysis of PLA, PETG, and Carbon Fiber Reinforced PETG

El Mehtedi,

Buonadonna,

El Mohtadi

et al. 2024

Preprint

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Fused deposition modeling (FDM) is widely applied in various fields due to its affordability and ease of use. However, it faces challenges such as achieving high surface quality, precise dimensional tolerance and overcoming anisotropic mechanical properties. This paper analyzes and compare the machinability of 3D printed PLA, PETG and carbon fiber reinforced PETG focusing on surface roughness and burr formation. A design of experiments (DoE) with a full factorial design was used, considering three factors: rotation speed, feed rate and depth of cut. Each factor had different levels: rotational speed at 3000, 5500 and 8000 rpm; feed rate at 400, 600 and 800 mm/min; and depth of cut at 0.2, 0.4, 0.6, and 0.8 mm. Machinability was evaluated by roughness and burr height using a profilometer for all the materials under the same milling conditions. To evaluate the statistical significance of the influence of various processing parameters on surface roughness and burr formation in 3D printed components made of three different materials PLA, PETG and carbon fiber reinforced PETG, an analysis of variance (ANOVA) test was conducted. This analysis investigated whether variations in rotational speed, feed rate and depth of cut resulted in measurable and significant differences in machinability results. Results showed that milling parameters significantly affect roughness and burr formation, with optimal conditions for minimizing any misalignment highlighting the trade-offs in parameter selection. These results provide insights into the post-processing of FDM-printed materials with milling, indicating the need for a balanced approach to parameter selection based on application-specific requirements.

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“…Additive Manufacturing (AM), also known as 3D printing, is a well-established technology gaining an ever-rising interest in several industrial branches ranging from automotive to aerospace, civil, and biomedical engineering [1][2][3]. Compared to conventional manufacturing processes, AM is able to produce intricately shaped parts at a cost-effective rate, facilitate swift processes, allow rapid prototyping, and diminish scrap production [4].…”

Section: Introductionmentioning

confidence: 99%

Surface Quality Related to Face Milling Parameters in 3D Printed Carbon Fiber-Reinforced PETG

El Mehtedi,

Buonadonna,

Loi

et al. 2024

J. Compos. Sci.

Self Cite

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Three-dimensional printing technology holds significant potential for enhancing the flexibility and cost-efficiency of producing carbon fiber-reinforced polymer composites (CFRPs). However, it faces limitations such as challenges in achieving high surface qualityand precise dimensional accuracy and managing the distinctive anisotropic mechanical properties that it demonstrates. This study aims to explore the machinability of 3D printed PETG infused with 20% short carbon fiber and to assess the resulting surface roughness and burr formation. Employing a Design of Experiments (DoE) approach, three factors were considered: rotational speed, feed rate, and depth of cut. These factors were tested at varying levels—rotational speeds of 3000, 5500, and 8000 rpm; feed rates of 400, 600, and 800 mm/min; and depth of cut values of 0.2, 0.4, 0.6, and 0.8 mm. The evaluation of machinability relied on two key response parameters: surface roughness (Sa) determined from the milled surface and burr height measured on both sides using a roughness meter. The findings revealed a significant influence of milling parameters on both roughness and burr formation. However, the ideal conditions for minimizing roughness and reducing burr formation did not align. Furthermore, a comparative analysis was conducted between these results and the machinability of PETG under similar conditions.

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Effects of milling parameters on roughness and burr formation in 3D- printed PLA components

Cited by 11 publications

References 16 publications

Surface roughness and dimension accuracy data from hybrid manufacturing process using PLA material

Surface roughness and dimension accuracy data from hybrid manufacturing process using PLA material

Optimizing Milling Parameters for Enhanced Machinability of 3D‐Printed Materials: An Analysis of PLA, PETG, and Carbon Fiber Reinforced PETG

Surface Quality Related to Face Milling Parameters in 3D Printed Carbon Fiber-Reinforced PETG

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