Optimization of Process Parameters in Fused Deposition Modeling Using Weighted Principal Component Analysis

Abstract

Fused deposition modeling (FDM) is a process by which functional parts can be produced rapidly through deposition of fused layers of material according to a numerically defined cross-sectional geometry. Literature suggests that process parameters largely influence on quality characteristics of rapid prototyping (RP) parts. A functional part is subjected to different loading conditions in actual practice. Therefore, process parameters need to be determined in such a way that they collectively optimize more than one response simultaneously. To address this issue, effect of important process parameters viz., layer thickness, orientation, raster angle, raster width, and air gap have been studied. The responses considered in this study are mechanical property of FDM produced parts such as tensile, bending and impact strength. The multiple responses are converted into a single response using principal component analysis (PCA) so that influence of correlation among the responses can be eliminated. Resulting single response is nothing but the weighted sum of three principal components that explain almost hundred percent of variation. The experiments have been conducted in accordance with Taguchi's orthogonal array to reduce the experimental runs. The results indicate that all the factors such as layer thickness, orientation, raster angle, raster width and air gap and interaction between layer thickness and orientation significantly influence the response. Optimum parameter settings have been identified to simultaneously optimize three responses. The mechanism of failure is explained with the help of SEM micrographs.

Profile monitoring based quality control method for fused deposition modeling process

“…Fang et al (1998) proposed FDM prototype internal defect detection method using image processing technology. Many scholars have also studied the optimization of process parameters, because layer thickness, temperature, speed and other process parameters have a great impact on the part quality (Garg et al 2014;Thorsten et al 2014;Mohamed et al 2016;Sbriglia et al 2016;Sood et al 2011;Luo et al 2016). Rao et al (2015) used multi-sensor to monitor the manufacturing process and studied the influence on the surface roughness of the parameters, such as material extrusion speed, layer thickness, and extruder temperature.…”

The Quantitative Research of Interaction between Key Parameters and the Effects on Mechanical Property in FDM

“…Functional relationship between process parameters and strength (tensile, flexural, and impact) was determined using response surface methodology with experimental factors of layer thickness, build orientation, raster angle, raster width, and air gap [8]. Sood et al [9] further examined the effect of these same five process parameters on the compressive strength of test specimens and developed a predictive equation. Their results displayed the importance of interfiber bond strength and the control of distortion during the build process.…”

Optimisation of orthosis products

“…Due to the nature of FDM printing, the material is extruded through the nozzle at 175 ° C in a build chamber maintained at 50 ° C. As the nozzle deposits material in the X-Y plane by layer to build the sample, temperature differentials exist within the material deposited. Once the material is laid, it cools from 175 °C to the chamber temperature of 50 ° C. An increased temperature gradient exists within the layers as the material being laid is at a higher temperature than already deposited layers, introducing residual stresses consequence of shrinkage (Sood, 2011). Additionally, building the model in layers, allows for poor layeradhesion which adversely affect the mechanical properties (Sood, 2011).…”

“…However, currently AM techniques especially FDM are inferior in some cases (Ligon, 2017). The mechanical properties of parts produced via FDM have strong dependence on the process parameters such as road width, raster angle, orientation of build, layer thickness and air gaps have significant influence over strength properties of the 3D printed part (Sood, 2011) (Centre, 2016. As FDM methods deposit semi-molten material directionally onto a build area, it results in anisotropic materials and introduces residual stresses from shrinkage, weak interlayer bonds and interlayer porosity (Sood, 2011).…”

“…The mechanical properties of parts produced via FDM have strong dependence on the process parameters such as road width, raster angle, orientation of build, layer thickness and air gaps have significant influence over strength properties of the 3D printed part (Sood, 2011) (Centre, 2016. As FDM methods deposit semi-molten material directionally onto a build area, it results in anisotropic materials and introduces residual stresses from shrinkage, weak interlayer bonds and interlayer porosity (Sood, 2011). Therefore, reproducibility of components with accurate properties depends significantly on the process parameters during manufacture, as well as limiting the temperature effects a consequence of poor temperature control (Omar Ahmed Mohamed, 2016).…”