Experimental Investigation and Prediction of Mechanical Properties in a Fused Deposition Modeling Process

Abstract

Additive manufacturing, also known as three-dimensional printing, is a computer-controlled advanced manufacturing process that produces three-dimensional items by depositing materials directly from a computer-aided design model, usually in layers. Due to its capacity to manufacture complicated objects utilizing a wide range of materials with outstanding mechanical qualities, fused deposition modeling is one of the most commonly used additive manufacturing technologies. For printing high-quality components with appropriate mechanical qualities, such as tensile strength and flexural strength, the selection of adequate processing parameters is critical. Experimentally, the influence of process parameters such as the raster angle, printing orientation, air gap, raster width, and layer height on the tensile strength of fused deposition modeling printed items was examined in this work. Through analysis of variance, the impact of each parameter was measured and rated. The system’s response was predicted using an adaptive neuro-fuzzy technique and an artificial neural network. In Minitab software, the Box-Behnken response surface experimental design was used to generate 46 experimental trials, which were then printed using acrylonitrile butadiene styrene polymer materials on a three-dimensional forge dreamer II fused deposition modelling printing machine. The results revealed that the raster angle, air gap, and raster width had significant impacts on the tensile strength. The adaptive neuro-fuzzy approach and artificial neural network predicted tensile strength accurately with an average percentage error of 0.0163 percent and 1.6437 percent, respectively. According to the findings, the model and experimental data are in good agreement.

Artificial Neural Network-Based Predictive Model for Finite Element Analysis of Additive-Manufactured Components

“…A study by Tura et al [4] used predictive models to determine, to a good degree of accuracy, the effects of parameters such as raster angle, orientation angle, air gap, raster width, and layer height on the mechanical properties of FDM-manufactured parts using ABS material. Studies by Yadav D. et al [5] were carried out on improving the tensile strength of additive manufactured parts by employing neural networks trained on parameters such as infill density, extrusion temperature, and material density, showing a 4.54% improvement in subsequent samples.…”

Dimensional Methods Used in the Additive Manufacturing Process

“…The earlier approaches mentioned above were followed by powder bed fusion processes using different printing techniques, such as direct metal laser sintering (DMLS), EBM, selective heat sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS), which have been widely analyzed in the literature [ 54 , 55 , 56 , 57 , 58 , 59 , 60 , 61 , 62 , 63 , 64 , 65 , 66 , 67 , 68 , 69 , 70 , 71 , 72 , 73 , 74 , 75 , 76 , 77 , 78 , 79 , 80 , 81 , 82 , 83 , 84 , 85 , 86 ].…”

“…Other printing technologies followed, such as the so-called sheet lamination processes, including ultrasonic additive manufacturing (UAM) and LOM [ 72 , 74 , 84 , 87 , 88 , 89 , 90 , 91 , 92 , 93 ]. UAM uses sheets or ribbons of metal, bonded together using ultrasonic welding, whereas LOM, instead of welding, uses layer-by-layer glued-paper deposition to form objects.…”

The Upper Limb Orthosis in the Rehabilitation of Stroke Patients: The Role of 3D Printing

“…Material extrusion 3D printers are the most diffused, user-friendly and low-cost. The fused filament (typically PLA = 20-40 €/kg, quality dependent) is heated to create the final 3D-printed object [45], or a syringe extrudes hydrogels or fluids. Both of these technologies have a wide range of materials, but with material extrusion technologies we can print more than one material in the same printing process, supporting sustainability when adopted with biodegradable materials (one piece for a patient requires a mandatory recycling approach) [46] or bioresorbable materials [47].…”