Optimization of FDM Printing Process Parameters on Surface Finish, Thickness, and Outer Dimension with ABS Polymer Specimens Using Taguchi Orthogonal Array and Genetic Algorithms

Chohan, Jasgurpreet Singh; Kumar, Raman; Yadav, Aniket; Chauhan, Piyush; Singh, Sandeep; Sharma, Shubham; Li, Changhe; Dwivedi, Shashi Prakash; Rajkumar, S.

doi:10.1155/2022/2698845

Cited by 33 publications

(11 citation statements)

References 65 publications

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“…The studied parameters by the proposed computational model provide insight and understanding of how these process parameters tune the properties such as voids and mechanical properties. To optimize the entire FDM method, the proposed model could be combined with the optimization algorithm enhancing the effectiveness of the model (Chohan et al , 2022; Fountas and Vaxevanidis, 2021; Yodo and Dey, 2021). Future research is directed toward developing the optimized model by using algorithms in conjunction with the developed computational model.…”

Section: Resultsmentioning

confidence: 99%

Geometric void-multiscale model for evaluating the effect of bead width and layer height on voids in FDM parts

Sheikh

Behdinan

2023

RPJ

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Purpose This paper aims to present a geometrical void model in conjunction with a multiscale method to evaluate the effect of interraster distance, bead (raster) width and layer height, on the voids concentration (volume) and subsequently calculate the final mechanical properties of the fused deposition modeling parts at constant infill. Design/methodology/approach A geometric model of the voids inside the representative volume element (RVE) is combined with a two-scale asymptotic homogenization method. The RVEs are subjected to periodic boundary conditions solved by finite element (FE) to calculate the effective mechanical properties of the corresponding RVEs. The results are validated with literature and experiments. Findings Bead width from 0.2 to 0.3 mm, reported a decrease of 25% and 24% void volume for a constant layer height (0.1 and 0.2 mm – 75% infill). It is reported that the void’s volume increased up to 14%, 32% and 36% for 75%, 50% and 25% infill by varying layer height (0.1–0.2 and 0.3 mm), respectively. For elastic modulus, 14%, 9% and 10% increase is reported when the void’s volume is decreased from 0.3 to 0.1 mm at a constant 75% infill density. The bead width and layer height have an inverse effect on voids volume. Originality/value This work brings values: a multiscale-geometric model capable of predicting the voids controllability by varying interraster distance, layer height and bead width. The idealized RVE generation slicer software and Solidworks save time and cost (<10 min, $0). The proposed model can effectively compute the mechanical properties together with the voids analysis.

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Section: Resultsmentioning

confidence: 99%

Geometric void-multiscale model for evaluating the effect of bead width and layer height on voids in FDM parts

Sheikh

Behdinan

2023

RPJ

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“…A broad range of patterns such as grid, triangle, zigzag (3), and concentric (2) were generated and produced by FDM printers [ 54 ], where pattern 2 showed improved results. Another study [ 62 ] reported that a linear pattern (1) is better than a triangle and tetrahedral pattern. Thus, there was a need to evaluate between pattern “1” and pattern “2”.…”

Section: Resultsmentioning

confidence: 99%

Parametric Effects of Fused Filament Fabrication Approach on Surface Roughness of Acrylonitrile Butadiene Styrene and Nylon-6 Polymer

et al. 2022

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This research objective is to optimize the surface roughness of Nylon-6 (PA-6) and Acrylonitrile Butadiene Styrene (ABS) by analyzing the parametric effects of the Fused Filament Fabrication (FFF) technique of Three-Dimensional Printing (3DP) parameters. This article discusses how to optimize the surface roughness using Taguchi analysis by the S/N ratio, ANOVA, and modeling methods. The effects of ABS parameters (initial line thickness, raster width, bed temperature, build pattern, extrusion temperature, print speed, and layer thickness) and PA-6 parameters (layer thickness, print speed, extrusion temperature, and build pattern) were investigated with the average surface roughness (Ra) and root-mean-square average surface roughness (Rq) as response parameters. Validation tests revealed that Ra and Rq decreased significantly. After the optimization, the Ra-ABS and Rq-PA-6 for the fabricated optimized values were 1.75 µm and 21.37 µm, respectively. Taguchi optimization of Ra-ABS, Rq-ABS, Ra-PA-6, and Rq-PA-6 was performed to make one step forward to use them in further research and prototypes.

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“…The Taguchi method helped determine that the print speed is the most influential printing parameter considering the surface roughness. [ 67 ] Other researchers evaluated 3D-printed parts using coordinate metrology. Yankov et al used an SLA 3D printer to create micro-squares.…”

Section: Methods Of Metrologymentioning

confidence: 99%

Statistical methods for design and testing of 3D-printed polymers

et al. 2023

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Different statistical methods are used in various fields to qualify processes and products, especially in emerging technologies like Additive Manufacturing (AM) or 3D printing. Since several statistical methods are being employed to ensure quality production of the 3D-printed parts, an overview of these methods used in 3D printing for different purposes is presented in this paper. The advantages and challenges, to understanding the importance it brings for design and testing optimization of 3D-printed parts are also discussed. The application of different metrology methods is also summarized to guide future researchers in producing dimensionally-accurate and good-quality 3D-printed parts. This review paper shows that the Taguchi Methodology is the commonly-used statistical tool in optimizing mechanical properties of the 3D-printed parts, followed by Weibull Analysis and Factorial Design. In addition, key areas such as Artificial Intelligence (AI), Machine Learning (ML), Finite Element Analysis (FEA), and Simulation require more research for improved 3D-printed part qualities for specific purposes. Future perspectives are also discussed, including other methods that can help further improve the overall quality of the 3D printing process from designing to manufacturing. Graphical abstract

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Optimization of FDM Printing Process Parameters on Surface Finish, Thickness, and Outer Dimension with ABS Polymer Specimens Using Taguchi Orthogonal Array and Genetic Algorithms

Cited by 33 publications

References 65 publications

Geometric void-multiscale model for evaluating the effect of bead width and layer height on voids in FDM parts

Geometric void-multiscale model for evaluating the effect of bead width and layer height on voids in FDM parts

Parametric Effects of Fused Filament Fabrication Approach on Surface Roughness of Acrylonitrile Butadiene Styrene and Nylon-6 Polymer

Statistical methods for design and testing of 3D-printed polymers

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