IRJET- Study of Fused Deposition Modeling Process Parameters for Polycarbonat...IRJET Journal
This document describes a study on the effects of process parameters on parts manufactured using fused deposition modeling (FDM) of a polycarbonate/acrylonitrile butadiene styrene (PC/ABS) blend material. Five parameters were selected - extrusion temperature, bed temperature, layer thickness, raster width, and printing speed. Experiments were conducted using an L8 orthogonal array design in Taguchi methodology. Parts were manufactured and measured for dimensional accuracy, surface roughness, and flatness without support structures. The goal was to determine optimal parameter settings to improve part quality characteristics for this material.
Experimental Investigation of Impact Strength for ABS Plus F.D.M. Parts using...IRJET Journal
The document experimentally investigates the impact strength of parts made from ABS Plus material using Fused Deposition Modeling (FDM). It examines the effects of three FDM process parameters - model interior, build orientation angle, and direction of rotation - on impact strength. Experiments were conducted according to a Design of Experiments using Taguchi method. Analysis of variance was used to determine the most influential parameter on impact strength, which was found to be build orientation angle. Regression analysis estimated the percentage of error between experimental and predicted results. In summary, the document explores how FDM process parameters affect the impact strength of ABS Plus parts through experiments using Taguchi method.
A review on different process parameters in FDM and their effects on various ...IRJET Journal
The document reviews different process parameters in fused deposition modeling (FDM) 3D printing and their effects on outputs like mechanical properties. It discusses parameters like layer thickness, orientation, infill density and printing speed. A lower layer thickness improves tensile strength by increasing bonding area. Orientation also affects properties, with the flat orientation tending to produce stronger parts. Infill density influences properties like tensile and flexural strength, with maximum values at 100% infill. Printing speed impacts material distribution and strength, with slower speeds producing stronger parts. The document aims to optimize these parameters to improve FDM part quality and properties.
IRJET- Simulation and Analysis of Step Light Mid Part using Mold Flow AnalysisIRJET Journal
This document summarizes a study that used mold flow analysis and the Taguchi method to optimize the injection molding process parameters for a step light mid part. The researchers 3D modeled the part, performed meshing, and selected polycarbonate as the material. They identified four critical parameters (mold surface temperature, melt temperature, injection time, and V/P switch over) and used an L9 orthogonal array to design experiments varying the parameters at three levels. Nine experiments were conducted and analyzed for signal-to-noise ratios to determine the optimum parameters. Simulation results showed fill time, pressure distribution, velocity, and identified the optimum gate location. Comparing the simulation and experimental trial results validated the optimized parameters.
This document reviews various methods that have been used to optimize process parameters for fused deposition modeling (FDM), including the Taguchi method and artificial neural networks (ANNs). It summarizes several studies that used Taguchi designs of experiments and analyses to determine the most significant FDM parameters (e.g., layer thickness, orientation, raster width) that influence properties like strength, flexibility, and dimensional accuracy. It also discusses applications of ANNs to predict experimental results and optimize parameters in other manufacturing processes like injection molding and electrical discharge machining. The document concludes that FDM parameter optimization is important for part quality and that Taguchi methods and ANNs are effective tools for design of experiments, analysis, prediction and optimization.
ANALYSIS OF SHRINKAGE AND WARPAGE DISPLACEMENT USING CONFORMAL COOLINGIRJET Journal
The document analyzes the use of conformal cooling channels in injection molding to reduce shrinkage and warpage compared to conventional cooling channels. It describes simulating injection molding processes using conformal and conventional cooling channels and comparing the results. The study finds conformal cooling channels significantly reduce shrinkage, warpage, and dimensional inaccuracies while improving cooling efficiency and reducing cycle times. In conclusion, conformal cooling offers advantages over conventional cooling that can enhance part quality and productivity.
Design &Manufacturing of Spur Gear using Fused Deposition ModelingIRJET Journal
This document describes a study on designing and manufacturing spur gears using fused deposition modeling (FDM) 3D printing. The researchers aim to evaluate the feasibility of using FDM for both direct tooling manufacturing and direct gear manufacturing. For direct manufacturing, the researchers will design and 3D print a spur gear and compare the costs to injection molding to determine the breakeven point where 3D printing becomes more cost-effective for small production volumes. For tooling, the researchers will design and 3D print FDM molds for producing wax patterns and evaluate the molds based on cost, time to manufacture, lifespan, and reusability compared to existing silicone rubber molds. The goal is to determine if FDM can be
SPRING BACK PREDICTION OF SHEET METAL IN DEEP DRAWING PROCESSIAEME Publication
Spring back is one of the most significant phenomenon that affect the accurateness of the sheet metal parts. In order to obtain fixed tolerances for the formed parts it is highly recommended to use such process parameters/tool geometry that allow a considerably diminishing of the spring back amount. A Finite Element (FE) model is developed for the 2- D numerical simulation of sheet metal deep drawing process (Parametric Analysis) by using HYPERFORM with the appropriate material properties (anisotropic material) and simplifies boundary conditions
IRJET- Study of Fused Deposition Modeling Process Parameters for Polycarbonat...IRJET Journal
This document describes a study on the effects of process parameters on parts manufactured using fused deposition modeling (FDM) of a polycarbonate/acrylonitrile butadiene styrene (PC/ABS) blend material. Five parameters were selected - extrusion temperature, bed temperature, layer thickness, raster width, and printing speed. Experiments were conducted using an L8 orthogonal array design in Taguchi methodology. Parts were manufactured and measured for dimensional accuracy, surface roughness, and flatness without support structures. The goal was to determine optimal parameter settings to improve part quality characteristics for this material.
Experimental Investigation of Impact Strength for ABS Plus F.D.M. Parts using...IRJET Journal
The document experimentally investigates the impact strength of parts made from ABS Plus material using Fused Deposition Modeling (FDM). It examines the effects of three FDM process parameters - model interior, build orientation angle, and direction of rotation - on impact strength. Experiments were conducted according to a Design of Experiments using Taguchi method. Analysis of variance was used to determine the most influential parameter on impact strength, which was found to be build orientation angle. Regression analysis estimated the percentage of error between experimental and predicted results. In summary, the document explores how FDM process parameters affect the impact strength of ABS Plus parts through experiments using Taguchi method.
A review on different process parameters in FDM and their effects on various ...IRJET Journal
The document reviews different process parameters in fused deposition modeling (FDM) 3D printing and their effects on outputs like mechanical properties. It discusses parameters like layer thickness, orientation, infill density and printing speed. A lower layer thickness improves tensile strength by increasing bonding area. Orientation also affects properties, with the flat orientation tending to produce stronger parts. Infill density influences properties like tensile and flexural strength, with maximum values at 100% infill. Printing speed impacts material distribution and strength, with slower speeds producing stronger parts. The document aims to optimize these parameters to improve FDM part quality and properties.
IRJET- Simulation and Analysis of Step Light Mid Part using Mold Flow AnalysisIRJET Journal
This document summarizes a study that used mold flow analysis and the Taguchi method to optimize the injection molding process parameters for a step light mid part. The researchers 3D modeled the part, performed meshing, and selected polycarbonate as the material. They identified four critical parameters (mold surface temperature, melt temperature, injection time, and V/P switch over) and used an L9 orthogonal array to design experiments varying the parameters at three levels. Nine experiments were conducted and analyzed for signal-to-noise ratios to determine the optimum parameters. Simulation results showed fill time, pressure distribution, velocity, and identified the optimum gate location. Comparing the simulation and experimental trial results validated the optimized parameters.
This document reviews various methods that have been used to optimize process parameters for fused deposition modeling (FDM), including the Taguchi method and artificial neural networks (ANNs). It summarizes several studies that used Taguchi designs of experiments and analyses to determine the most significant FDM parameters (e.g., layer thickness, orientation, raster width) that influence properties like strength, flexibility, and dimensional accuracy. It also discusses applications of ANNs to predict experimental results and optimize parameters in other manufacturing processes like injection molding and electrical discharge machining. The document concludes that FDM parameter optimization is important for part quality and that Taguchi methods and ANNs are effective tools for design of experiments, analysis, prediction and optimization.
ANALYSIS OF SHRINKAGE AND WARPAGE DISPLACEMENT USING CONFORMAL COOLINGIRJET Journal
The document analyzes the use of conformal cooling channels in injection molding to reduce shrinkage and warpage compared to conventional cooling channels. It describes simulating injection molding processes using conformal and conventional cooling channels and comparing the results. The study finds conformal cooling channels significantly reduce shrinkage, warpage, and dimensional inaccuracies while improving cooling efficiency and reducing cycle times. In conclusion, conformal cooling offers advantages over conventional cooling that can enhance part quality and productivity.
Design &Manufacturing of Spur Gear using Fused Deposition ModelingIRJET Journal
This document describes a study on designing and manufacturing spur gears using fused deposition modeling (FDM) 3D printing. The researchers aim to evaluate the feasibility of using FDM for both direct tooling manufacturing and direct gear manufacturing. For direct manufacturing, the researchers will design and 3D print a spur gear and compare the costs to injection molding to determine the breakeven point where 3D printing becomes more cost-effective for small production volumes. For tooling, the researchers will design and 3D print FDM molds for producing wax patterns and evaluate the molds based on cost, time to manufacture, lifespan, and reusability compared to existing silicone rubber molds. The goal is to determine if FDM can be
SPRING BACK PREDICTION OF SHEET METAL IN DEEP DRAWING PROCESSIAEME Publication
Spring back is one of the most significant phenomenon that affect the accurateness of the sheet metal parts. In order to obtain fixed tolerances for the formed parts it is highly recommended to use such process parameters/tool geometry that allow a considerably diminishing of the spring back amount. A Finite Element (FE) model is developed for the 2- D numerical simulation of sheet metal deep drawing process (Parametric Analysis) by using HYPERFORM with the appropriate material properties (anisotropic material) and simplifies boundary conditions
A Review on Finite Element Analysis of Automobile roof header Manufactured By...ijiert bestjournal
In stamping operations,sheet metal is formed into a desired s hape by pressing it in a hydraulic or mechanical press between suitably shaped dies. As a predominant manufacturing pr ocess,sheet metal forming has been widely used for the production of automobiles,aircraft,home appliance s,beverage cans and many other industrial and commercial products. Given that the press force itsel f is an integral of the contact pressure distribution over the die and binder contact interfaces,it is concei vable that defects may be better identified by analyzing the contact pressure distribution directly at the tooling-work piece interface.
IRJET- Effect of Gasoline Exposure on the Mechanical Properties of PLA an...IRJET Journal
This document studies the effect of gasoline exposure on the mechanical properties of PLA and ABS materials processed by fused filament fabrication (FFF). Specimens of PLA and ABS were manufactured according to ASTM standards and submerged in gasoline for 84 hours. Tensile strength, flexural strength, and hardness tests were then conducted on the exposed specimens. The results showed that PLA retained most of its mechanical properties after exposure, while ABS became soft and rubbery with a significant reduction in tensile, flexural strength and hardness. The study aims to determine the suitability of PLA and ABS for applications that may involve interaction with gasoline.
This document summarizes research on optimizing cutting parameters to achieve desired surface roughness in turning operations. The research uses design of experiments to collect data on surface roughness under varying cutting speed, feed, and depth of cut. Regression equations are developed to relate the parameters to surface roughness. Genetic algorithms and particle swarm optimization are then applied to optimize the parameters to minimize surface roughness. The results from genetic algorithms and particle swarm optimization are compared to determine which technique finds a better optimal parameter combination for achieving the desired surface roughness.
Optimization of Cutting Parameters Using Genetic Algorithm and Particle Swar...IJMER
In machining operations, achieving desired surface quality features of the machined product,
is really a challenging job. Because, these quality features are highly correlated and are expected to be
influenced directly or indirectly by the direct effect of process parameters or their interactive effects
(i.e. on process environment). However, the extents of significant influence of the process parameters
are different for different responses. Therefore, optimization of surface roughness is a multi-factor,
multi-objective optimization problem. Therefore, to solve such a multi-objective optimization problem, it
is felt necessary to identify the optimal parametric combination, following which all objectives could be
optimized simultaneously. In this context, it is essential to convert all the objective functions into an
equivalent single objective function or overall representative function to meet desired multi-quality
features of the machined surface. The required multi-quality features may or may not be conflicting in
nature. The representative single objective function, thus calculated, would be optimized finally. In the
present work, Design of Experiment (DOE) with Design of Expect software, Mini Tab & optimized
using genetic algorithm by MAT Lab and Particle Swarm Optimization (PSO) by “C” program in
straight turning operation. Collected data related to surface roughness have been utilized for
optimization. Due to complexity of this machining optimization problem, a genetic algorithm (GA) and
Particle Swarm Optimization (PSO) are applied to resolve the problem and the results obtained from
GA and PSO are compared
This document reviews research on optimizing process parameters for sheet metal forming operations using statistical tools. It discusses how parameters like blank holding pressure and material thickness can be evaluated at different levels to minimize defects like wrinkles, tearing and thinning. Data collected during experiments will undergo statistical analysis using ANOVA and Taguchi methods to arrive at an optimized solution. Previous studies that analyzed various process parameters to optimize objectives are summarized. The document aims to determine significant parameters that can render defect-free parts when set to recommended values.
CHARACTERIZATION AND ANALYSIS OF MECHANICAL PROPERTIES FOR 3D PRINTING MATERIALSIRJET Journal
This document analyzes and compares the mechanical properties of common 3D printing materials like polylactic acid (PLA) and Lay Wood. It first reviews previous literature that has studied properties like tensile strength, elastic modulus, impact strength and crystallinity of 3D printed PLA under different conditions. It then describes conducting tensile, compressive and hardness tests on PLA and Lay Wood specimens printed using a Creality 10-S 3D printer. The results of these tests are presented in tables showing the mechanical properties of each material.
Experimental Studies on Effect of Layer Thickness on Surface Finish using FDMIRJET Journal
This document discusses an experimental study on the effect of layer thickness on surface finish in fused deposition modeling (FDM) 3D printing. It aims to establish a logical relationship between surface roughness and layer thickness by 3D printing test components with varying layer thicknesses and measuring the surface roughness of each. The study uses a Flashforge Guide IIs printer and polylactic acid (PLA) material. It reviews relevant literature on factors that influence FDM part quality like layer thickness, build orientation, and infill density. The objectives are to examine how FDM process parameters like layer thickness affect surface roughness and optimize parameters for better part quality.
Investigation of post processing techniques to reduce the surface roughness o...iaemedu
This document discusses investigating post-processing techniques to reduce the surface roughness of parts created through Fused Deposition Modeling (FDM). It analyzes the use of chemical treatment methods to improve surface finish of ABS plastic FDM parts. The study uses Design of Experiments (DOE) and Analysis of Variance (ANOVA) to determine the significant factors that affect surface roughness from chemical treatment. These factors include concentration of the chemical solution, temperature of the chemical bath, initial surface roughness of the parts, and time of exposure to the chemicals. Two different chemicals (dimethylketone and methylethylketone) are analyzed at various concentration levels and temperatures, with parts of different initial roughness and exposure times, to determine the optimal
Investigation of post processing techniques to reduce the surfaceiaemedu
This document summarizes an investigation into post-processing techniques to reduce the surface roughness of parts created through fused deposition modeling (FDM). Specifically, it examines using chemical treatment methods with different chemicals, concentrations, temperatures, exposure times, and initial part roughnesses. A statistical design of experiments approach is used to identify significant factors affecting surface finish and optimize the chemical treatment process. Results from applying this method to ABS plastics show that simple, inexpensive chemical treatments can satisfactorily improve the surface finish of FDM parts.
A Review: Fused Deposition Modeling – A Rapid Prototyping ProcessIRJET Journal
This document provides an overview of fused deposition modeling (FDM), a rapid prototyping process. FDM involves layer-by-layer deposition of thermoplastic materials using an extrusion nozzle to build 3D parts from CAD data. Key aspects covered include:
- The FDM process involves heating and extruding plastic filaments through a nozzle to build parts layer-by-layer.
- Common thermoplastics used include ABS and PLA, and process parameters like orientation, layer thickness, and raster width impact part quality.
- FDM can produce functional prototypes and has applications in industries like aerospace, consumer goods, and automotive for prototyping, tooling, and low-volume production
Process parameter optimization of SLM process and application of Taguchi appr...ijsrd.com
Selective Laser Melting (SLM) is an emerging powder based additive layer manufacturing technology that used to fabricate three-dimensional fully functional parts from metal powders by fusing the material in a layer by layer manner as per a CAD model. The quality of SLM produced parts is significantly affected by various manufacturing parameters of SLM machine. Hence optimization of SLM process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of SLM process and application of Taguchi approach. This review of work can be helpful to the other researchers to carry out further work in the same era.
Manufacturing Process Simulation Based Geometrical Design for Complicated PartsLiu PeiLing
More than ever, it is critical that products are designed and manufactured right the first time. Design for Manufacturing (DFM) methodology has been recognized as one of the most effective ways to short product lifecycle time and reduce manufacturing cost. The main function of DFM in the detailed design stage is analyzing the manufacturability of the part. Various existing manufacturability evaluation methods have their limitations. In this paper, a new approach to DFM for the complicated parts is proposed. Instead of checking the manufacturability following the design, the in-process model resulting from the manufacturing process simulation is used to generate process dependent geometry surfaces at the design stage. The definition of the manufacturing process dependent geometry is given, and the methodology for creation of in-process model is presented in details.
This document summarizes an article from the International Journal of Mechanical Engineering and Technology that discusses optimizing critical processing parameters for plastic injection molding. It begins by stating that determining optimal initial process parameters is important for productivity, quality and costs. It then outlines the objectives of identifying optimized levels for factors like temperature and pressure. The methodology proposed uses Taguchi design of experiments and Moldflow simulation software to optimize parameters for different materials like polypropylene. The scope is to study injection molding parameters for polypropylene and provide recommendations for parameter settings based on material and geometry.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
Experimental Investigation and Parametric Studies of Surface Roughness Analys...IJMER
The modern machining industries are focused on achieving high quality, in terms of
part/component accuracy, surface finish, high production rate and increase in product life. Surface
roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter.
The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other
parameters such as cutting force and power consumption in different conditions.
3D Printable Concrete: Mixture Design, Simulation & Test MethodsIRJET Journal
This document discusses 3D printable concrete, including its mixture design, simulation, and testing methods. It begins with an abstract that outlines the benefits of 3D concrete printing for construction projects but notes challenges around standardization and accessibility.
The document then reviews literature on 3D printable concrete mix design, concluding that current codes and standards do not apply and a trial-and-error approach is typically used. It introduces the concept of "manual extrusion" or handheld 3D printing to experimentally test concrete mixtures in a cost-effective way.
The methodology section describes developing a manual extruder, studying existing mixture data, optimizing aggregate packing using software, conducting extrusion and printing trials, and testing samples to improve the
Optimization of Abrasive Water Jet of Drillingssuser0811ec
This document discusses optimization of drilling process parameters for onyx composites using abrasive water jet machining (AWJM) followed by additive manufacturing. It first describes how additive manufacturing can produce onyx composites with fewer issues than conventional methods. It then discusses how machining of composites can cause delamination and surface roughness issues. The study uses Taguchi analysis to optimize AWJM drilling parameters for onyx composites made via additive manufacturing. Regression models, genetic algorithms, and moth-flame optimization are used to predict delamination damage and surface roughness during drilling.
The document summarizes the design and manufacturing process of a compound tool for a speedometer component. It includes sections on the presentation flow, abstract, introduction, literature review, problem statement, objectives, methodology, flow chart, calculations, design, progress, and references. The methodology section outlines the key steps in compound tooling which performs multiple operations in a single stroke using a blanking tool and piercing tool. The design section describes the main components of the compound tool like the punch, die plate, forming punch, guide bush, and pins. The objectives are to simultaneously perform more than one operation per stroke to reduce costs and improve efficiency over separate machines for each operation.
A Review on Optimization of Cutting Parameters for Improvement of Surface Rou...IRJET Journal
This document summarizes a study that used the Taguchi method and Grey Taguchi approach to optimize cutting parameters for improving surface roughness and tool life during low carbon steel turning. The study used an L27 orthogonal array to experiment with cutting speed, feed rate, depth of cut, and corner radius. Surface roughness and flank wear were evaluated as output parameters. Analysis of variance found that cutting speed most significantly affects surface roughness and flank wear, followed by depth of cut, feed rate, and corner radius. The optimized parameters were determined to be a cutting speed of 325m/min, feed rate of 0.1 mm/rev, depth of cut of 0.25mm, and corner radius of 0.8mm.
IRJET- Design of Spoon Mold using Flow Analysis and Higher End Design SoftwareIRJET Journal
This document discusses the design of a multi-cavity mold for producing plastic spoons using flow analysis software. The objectives are to reduce defects and optimize the mold design. The methodology involves 3D modeling the spoon, designing a multi-cavity mold, and performing flow analysis simulations to determine the optimal gate locations and process parameters. This optimized design aims to improve productivity by producing more spoons per cycle in the multi-cavity mold compared to previous single-cavity mold designs.
A Review on Finite Element Analysis of Automobile roof header Manufactured By...ijiert bestjournal
In stamping operations,sheet metal is formed into a desired s hape by pressing it in a hydraulic or mechanical press between suitably shaped dies. As a predominant manufacturing pr ocess,sheet metal forming has been widely used for the production of automobiles,aircraft,home appliance s,beverage cans and many other industrial and commercial products. Given that the press force itsel f is an integral of the contact pressure distribution over the die and binder contact interfaces,it is concei vable that defects may be better identified by analyzing the contact pressure distribution directly at the tooling-work piece interface.
IRJET- Effect of Gasoline Exposure on the Mechanical Properties of PLA an...IRJET Journal
This document studies the effect of gasoline exposure on the mechanical properties of PLA and ABS materials processed by fused filament fabrication (FFF). Specimens of PLA and ABS were manufactured according to ASTM standards and submerged in gasoline for 84 hours. Tensile strength, flexural strength, and hardness tests were then conducted on the exposed specimens. The results showed that PLA retained most of its mechanical properties after exposure, while ABS became soft and rubbery with a significant reduction in tensile, flexural strength and hardness. The study aims to determine the suitability of PLA and ABS for applications that may involve interaction with gasoline.
This document summarizes research on optimizing cutting parameters to achieve desired surface roughness in turning operations. The research uses design of experiments to collect data on surface roughness under varying cutting speed, feed, and depth of cut. Regression equations are developed to relate the parameters to surface roughness. Genetic algorithms and particle swarm optimization are then applied to optimize the parameters to minimize surface roughness. The results from genetic algorithms and particle swarm optimization are compared to determine which technique finds a better optimal parameter combination for achieving the desired surface roughness.
Optimization of Cutting Parameters Using Genetic Algorithm and Particle Swar...IJMER
In machining operations, achieving desired surface quality features of the machined product,
is really a challenging job. Because, these quality features are highly correlated and are expected to be
influenced directly or indirectly by the direct effect of process parameters or their interactive effects
(i.e. on process environment). However, the extents of significant influence of the process parameters
are different for different responses. Therefore, optimization of surface roughness is a multi-factor,
multi-objective optimization problem. Therefore, to solve such a multi-objective optimization problem, it
is felt necessary to identify the optimal parametric combination, following which all objectives could be
optimized simultaneously. In this context, it is essential to convert all the objective functions into an
equivalent single objective function or overall representative function to meet desired multi-quality
features of the machined surface. The required multi-quality features may or may not be conflicting in
nature. The representative single objective function, thus calculated, would be optimized finally. In the
present work, Design of Experiment (DOE) with Design of Expect software, Mini Tab & optimized
using genetic algorithm by MAT Lab and Particle Swarm Optimization (PSO) by “C” program in
straight turning operation. Collected data related to surface roughness have been utilized for
optimization. Due to complexity of this machining optimization problem, a genetic algorithm (GA) and
Particle Swarm Optimization (PSO) are applied to resolve the problem and the results obtained from
GA and PSO are compared
This document reviews research on optimizing process parameters for sheet metal forming operations using statistical tools. It discusses how parameters like blank holding pressure and material thickness can be evaluated at different levels to minimize defects like wrinkles, tearing and thinning. Data collected during experiments will undergo statistical analysis using ANOVA and Taguchi methods to arrive at an optimized solution. Previous studies that analyzed various process parameters to optimize objectives are summarized. The document aims to determine significant parameters that can render defect-free parts when set to recommended values.
CHARACTERIZATION AND ANALYSIS OF MECHANICAL PROPERTIES FOR 3D PRINTING MATERIALSIRJET Journal
This document analyzes and compares the mechanical properties of common 3D printing materials like polylactic acid (PLA) and Lay Wood. It first reviews previous literature that has studied properties like tensile strength, elastic modulus, impact strength and crystallinity of 3D printed PLA under different conditions. It then describes conducting tensile, compressive and hardness tests on PLA and Lay Wood specimens printed using a Creality 10-S 3D printer. The results of these tests are presented in tables showing the mechanical properties of each material.
Experimental Studies on Effect of Layer Thickness on Surface Finish using FDMIRJET Journal
This document discusses an experimental study on the effect of layer thickness on surface finish in fused deposition modeling (FDM) 3D printing. It aims to establish a logical relationship between surface roughness and layer thickness by 3D printing test components with varying layer thicknesses and measuring the surface roughness of each. The study uses a Flashforge Guide IIs printer and polylactic acid (PLA) material. It reviews relevant literature on factors that influence FDM part quality like layer thickness, build orientation, and infill density. The objectives are to examine how FDM process parameters like layer thickness affect surface roughness and optimize parameters for better part quality.
Investigation of post processing techniques to reduce the surface roughness o...iaemedu
This document discusses investigating post-processing techniques to reduce the surface roughness of parts created through Fused Deposition Modeling (FDM). It analyzes the use of chemical treatment methods to improve surface finish of ABS plastic FDM parts. The study uses Design of Experiments (DOE) and Analysis of Variance (ANOVA) to determine the significant factors that affect surface roughness from chemical treatment. These factors include concentration of the chemical solution, temperature of the chemical bath, initial surface roughness of the parts, and time of exposure to the chemicals. Two different chemicals (dimethylketone and methylethylketone) are analyzed at various concentration levels and temperatures, with parts of different initial roughness and exposure times, to determine the optimal
Investigation of post processing techniques to reduce the surfaceiaemedu
This document summarizes an investigation into post-processing techniques to reduce the surface roughness of parts created through fused deposition modeling (FDM). Specifically, it examines using chemical treatment methods with different chemicals, concentrations, temperatures, exposure times, and initial part roughnesses. A statistical design of experiments approach is used to identify significant factors affecting surface finish and optimize the chemical treatment process. Results from applying this method to ABS plastics show that simple, inexpensive chemical treatments can satisfactorily improve the surface finish of FDM parts.
A Review: Fused Deposition Modeling – A Rapid Prototyping ProcessIRJET Journal
This document provides an overview of fused deposition modeling (FDM), a rapid prototyping process. FDM involves layer-by-layer deposition of thermoplastic materials using an extrusion nozzle to build 3D parts from CAD data. Key aspects covered include:
- The FDM process involves heating and extruding plastic filaments through a nozzle to build parts layer-by-layer.
- Common thermoplastics used include ABS and PLA, and process parameters like orientation, layer thickness, and raster width impact part quality.
- FDM can produce functional prototypes and has applications in industries like aerospace, consumer goods, and automotive for prototyping, tooling, and low-volume production
Process parameter optimization of SLM process and application of Taguchi appr...ijsrd.com
Selective Laser Melting (SLM) is an emerging powder based additive layer manufacturing technology that used to fabricate three-dimensional fully functional parts from metal powders by fusing the material in a layer by layer manner as per a CAD model. The quality of SLM produced parts is significantly affected by various manufacturing parameters of SLM machine. Hence optimization of SLM process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of SLM process and application of Taguchi approach. This review of work can be helpful to the other researchers to carry out further work in the same era.
Manufacturing Process Simulation Based Geometrical Design for Complicated PartsLiu PeiLing
More than ever, it is critical that products are designed and manufactured right the first time. Design for Manufacturing (DFM) methodology has been recognized as one of the most effective ways to short product lifecycle time and reduce manufacturing cost. The main function of DFM in the detailed design stage is analyzing the manufacturability of the part. Various existing manufacturability evaluation methods have their limitations. In this paper, a new approach to DFM for the complicated parts is proposed. Instead of checking the manufacturability following the design, the in-process model resulting from the manufacturing process simulation is used to generate process dependent geometry surfaces at the design stage. The definition of the manufacturing process dependent geometry is given, and the methodology for creation of in-process model is presented in details.
This document summarizes an article from the International Journal of Mechanical Engineering and Technology that discusses optimizing critical processing parameters for plastic injection molding. It begins by stating that determining optimal initial process parameters is important for productivity, quality and costs. It then outlines the objectives of identifying optimized levels for factors like temperature and pressure. The methodology proposed uses Taguchi design of experiments and Moldflow simulation software to optimize parameters for different materials like polypropylene. The scope is to study injection molding parameters for polypropylene and provide recommendations for parameter settings based on material and geometry.
Experimental Investigation and Parametric Studies of Surface Roughness Analy...IJMER
The modern machining industries are focused on achieving high quality, in terms of part/component accuracy, surface finish, high production rate and increase in product life. Surface roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter. The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other parameters such as cutting force and power consumption in different conditions
Experimental Investigation and Parametric Studies of Surface Roughness Analys...IJMER
The modern machining industries are focused on achieving high quality, in terms of
part/component accuracy, surface finish, high production rate and increase in product life. Surface
roughness of machined components has received serious attention of researchers for many years. It has
been an important design feature and quality measure in machining process. There are a large number of
parameters which affect the surface roughness. The typical controllable parameters for the CNC machines
include cutting tool variables, work piece material variables, cutting conditions etc. The desired output is
surface roughness, material removal rate, tool wear, etc. Optimization of machining parameters needs to
determine the most significant parameter for required output. Many techniques are used for optimization
of machining parameters including Taguchi, RSM and ANOVA approach to determine most significant
parameter.
The present work is therefore in a direction to integrate effect of various parameters which affect
the surface roughness. This paper investigates the parameters affecting the surface roughness and / or
material removal rate with CNC turning process studied by researchers. It also discusses some other
parameters such as cutting force and power consumption in different conditions.
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1. Department of Mechanical Engineering
Academic Year: 2023-24
OPTIMIZATION OF PRINTING PARAMETERS IN
FUSED DEPOSITION MODELLING FOR IMPROVING
PART QUALITY AND MECHANICAL STRENGTH
21P35A0312 - M.V.K.RAHUL
20P31A0317 - C.ASHISH RAM
20P31A0332 - K.N.S.M.KIRAN
20P31A0333 - K.SRINIVAS
Under the Guidance of
Dr.CH.V.V.M.J.SATISH
Associate Professor
M.Tech, Phd
BATCH – 07:
2. Contents
• Abstract
• Literature Review
• Introduction
• Estimated CO-PO mapping
• Plan of Action
• Cost estimation Report
• Project Overview
• Methodology and Experimentation
• Results
• Conclusion
• References
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3. Abstract
This project seeks to optimize printing parameters in Fused Deposition Modeling
(FDM) to enhance part quality and improve the mechanical strength of the printed
part. FDM is a widely adopted 3D printing technology, and improving its efficiency
is crucial for advancing additive manufacturing. The project aims to systematically
investigate various printing parameters and their interactions to find an optimal
configuration that balances part quality, production time, and mechanical strength.
Through experimental research and analysis, the project aims to provide valuable
insights and guidelines for users aiming to maximize the benefits of FDM
technology, with a focus on fast and quality prototype production.
We are aiming to build a low cost 3d printer by purchasing various parts and
assembling them to perform our experimentation. By using CAD design and Slicing
software, we are going to vary the various process parameters like layer height,
extrusion temperature etc., and perform Design of Experiments(Taguchi Approach) to
find the optimal parameters suitable for our 3d printer built in order to obtain good
surface finish and improved mechanical strength of the printed parts.
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4. Introduction
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Additive manufacturing (AM), commonly known as 3D
printing, is the process of creating parts by accumulating material
layer upon layer, starting directly from a computer-aided design
model. There are many prominent advantages of AM that can be listed
out, such as direct manufacturing process without molds, unrestricted
to the complexity of product structure, unlimited in innovative and
creative design, high utilization of material and eco-friendly.
Nowadays, the use of 3D printing is increasingly popular not only
in prototype phase but also in finished product, in various fields
from aerospace, automotive to medical. Parallel to the rapid increase of 3D
printing use, it is essential to have an instruction for the optimal
process parameters to attain qualified products regards to
efficiency. In addition, due to the principle of 3D printing is adding
layer by layer material in order to make a finished part, product
mechanical property is the important quality criteria should be
considered.
5. Thus, investigating the effect of each process parameters on mechanical characteristics
of the FDM parts helps to adjust level of process variables leading to improvement in
quality of parts. There are various factors such as orientation angle, raster angle, layer
thickness, shell thickness, infill pattern, infill density, extrusion temperature, printing
speed which affect the ultimate tensile strength and surface finish for finished product.
The levels of these process parameters can be varied using a slicing software and by
finding the optimal levels of these process parameters, the response output variables
which are the mechanical properties of the printed parts can be optimized.
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6. Literature
In the past several years, researchers have examined the outcomes of 3D printing parameters on
key metrics of FDM to improve the condition of the part by maximizing yield strength and
ultimate tensile strength, among other mechanical properties.
1. Hassanifard and Hashemi [1] studied the effect of part’s build orientation and raster angle
on the strain-life fatigue of specimens made of Ultem 9085, polycarbonate (PC), and
polylactic acid (PLA). Parts were created based on ASTM D638-14 and ASTM D790-17
standards. The authors concluded that infill density affected the mechanical properties of
the printed part.
2. The aim of the work reported by Verbeeten et al. [2] was to investigate the strain-rate
dependence of the yield stress for tensile samples made of PLA, based on ISO 527-2
standard. Printing speed, infill orientation angle, and bed temperature were modified. One
of the conclusions of the study was that a change of infill orientation angle from 0 to 90°
provided anisotropic effects to the pieces.
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7. 3. Zhao et al. [3] explored the effect of printing angle and layer thickness on the mechanical
properties of specimens made of PLA. The standard used to fabricate the units was ISO 527-2-
2012. Tensile strength increased with higher values of printing angle and reduced ones of layer
thickness.
4. Tanoto et al. [4] evaluated dimensional accuracy, processing time, and tensile strength of 3D
printed components. The components were made of ABS, using FDM technology. The printing
plane and the orientation angle were selected as the response variables to be analyzed. The
specimens employed in the experimental trials belong to type IV, according to the ASTM D638-
02 standard. Printing time diminished when the part was oriented in the XZ plane at 90°. This
orientation also provided a specimen’s length value closer to the one of the ASTM standard.
5. The work of Alafaghani et al. [5] presented an experiment to determine the values of infill rate,
infill pattern, the orientation of the part, and layer thickness that enhanced dimensional accuracy
and mechanical properties of specimens made of PLA. The part design followed type IV
specifications according to the ASTM D638-15 standard. Lower values of fill density and shell
thickness and higher values of layer thickness and feed rate reduced the measured values.
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8. 6. Huynh et al. [6] considered the effect of infill rate, infill pattern, and layer thickness on the
dimensional precision of parts made of PLA using FDM. The piece was a CAD model created
by the authors, and an orthogonal array L27 was applied, along with a fuzzy approach to
optimize printing parameters.
7. The work of Padhi et al. [7] shows a comparison between the dimensional deviation of
printed specimens from the dimensions of a CAD model. An L27 orthogonal array allowed to
modify the infill angle, raster width, air gap, orientation of the part, and layer thickness. The
material of the specimens is ABS P400. A medium value for layer thickness and raster width,
the greatest one for the air gap and the least for orientation and raster angle, granted the
highest dimensional precision.
8. Mohamed et al. [8] investigated the dimensional accuracy of specimens made of a PCABS
blend, employing FDM. The process parameters that were modified are raster angle, raster
width, air gap, part orientation, layer thickness, and the number of contours. The geometry of
the specimens is according to the standards ASTM D5418-07 and ASTM D7028-07e1. The
layer thickness was the factor that affected all the responses.
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10. Plan of Action
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Sl. No Date/Duration Description
1 Week-1
18-01-24 to 24-01-24
Define Project Scope and Objectives:
Clearly outline the project's goals, including the
specific printing parameters to be optimized, cost
considerations, etc.,
2 Week-2
25-01-24 to 31-01-24
Cost Estimation and Budgeting:
Develop a detailed cost estimation for the project,
considering expenses related to materials, equipment
and other relevant factors.
3 Week-3
01-02-24 to 07-02-24
Review Existing Literature:
Conduct an in-depth review of relevant literature to
understand about our project goals
4 Week-4
08-02-24 to 14-02-24
Learn basic Designing for 3d printing:
Learn and practice designing simple 2d and
3d figures like cubes and cylinders in ONSHAPE
11. Sl. No Date/Duration Description
5 Week-5
15-02-24 to 21-02-24
Learn basics in Slicing Software:
Learn and Practice to use Ulti maker Cura Slicing
software and about the various parameters that can be
controlled for 3d printing
6 Week-6
22-02-24 to 28-02-24
Learn about Design of Experiments(DOE):
Study about the Design of Experiments(DOE) and
Taguchi Approach and practice using it in Minitab
7 Week-7
29-02-24 to 06-03-24
Purchase and Assemble the 3d Printer:
Purchase various parts and components and assemble
them to build our 3d printer
8 Week- 8
07-03-24 to 13-03-24
Practice printing on the 3d printer:
Practice designing and give sample prints in our 3d
printer
9 Week- 9
14-03-24 to 20-03-24
Designing a standard specimen for
experimentation:
Designing a standard test specimen for experimentation
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12. Sl. No Date/Duration Description
10 Week- 10
21-03-24 to 27-03-24
Printing the test specimens :
Printing all the required test specimens with
varying parameters on the 3d printer
11 Week- 11
28-03-24 to 03-04-24
Surface Roughness testing of printed parts:
Testing and obtaining required values of surface
roughness for the printed parts with Surface
roughness testing machine
12 Week- 12
04-04-24 to 10-04-24
Ultimate Tensile strength testing of printed
parts:
Testing the printed parts in UTM for obtaining the
strength values of all printed parts
13 Week- 13
11-04-24 to 17-04-24
Analysis of the results with Taguchi Approach:
Analysis and application of Taguchi Statistical
Approach to obtain optimal parameters
14 Week- 14
18-04-24 to 24-04-24
Verification and Document preparation:
Verification of the end results and document
preparation for the project
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13. Budget estimation
Sl.
No
Equipment/Parts Quantity Price per
Quantity
Total Price in INR
1 Print material 1 800 800
2 Nozzle Set 1 600 600
3 Stepper Motors 3 700 2100
4 Controller Board 1 700 700
5 Frame 1 3000 3000
6 Motion Components 1 1200 1200
7 Power supply unit 1 1000 1000
8 Print Bed 1 400 400
9 Extruder 1 5500 5500
10 Feeder System 1 1500 1500
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Total Budget Estimation = Rs.17000
14. Project Overview
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PARAMETER OPTIMIZATION IN FUSED DEPOSITION MODELLING:
In order to find the optimal levels of parameters for our assembled Any Cubic
Kobra 2 Neo 3D Printer for obtaining high mechanical strength and good
surface finish, we have considered 3 factors which are majorly influencing
the mechanical properties i.e., strength and surface roughness of the 3d
printed parts. The 3 factors are layer height, infill percent and extrusion
temperature. From the previous studies done by different researchers, layer
height is the main influencing factor behind the surface roughness of the 3d
printed parts and the factors layer height and infill percent and extrusion
temperature influence the strength of the printed parts.
15. • Layer Height:
• The thickness of each layer of deposited material is called the ‘layer height’.
• The surface quality of the finished part is proportional to how small the layer height
is; smaller layer heights result in smother surface finishes.
• For FDM printers, the number of layers is one
indicator of how much time a 3D print will take.
Choosing a smaller layer height will divide a 3D
model into more layers, increasing the print time.
For Any Cubic Kobra 2 Neo 3D Printer, the
recommended layer height in Cura is 0.2mm. And
Our nozzle diameter is 0.4mm. So, we have taken
3 levels of layer height from 0.2-0.3 mm.
Layer height : Level-1 : 0.20mm
Level-2 : 0.25mm
Level-3 : 0.30mm
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16. • Infill Density:
• Infill density is the “fullness” of the
inside of a part. In slicers, this is usually
defined as a percentage between 0 and 100.
Infill Density : Level-1 : 15%
Level-2 : 60%
Level-3 : 100%
• Extrusion Temperature:
• Extrusion temperature is the temperature the
extruder heats to during your print.
• PLA melts at extrusion temperatures from about
180°C.The suggested temperature is 200 °C and the
Maximum temperature the printer can attain is 260 °C
Extrusion Temperature : Level-1 : 200 °C
Level-2 : 230 °C
Level-3 : 260 °C
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17. Design Matrix for Experimentation
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S. No. FACTORS LEVEL 1 LEVEL 2 LEVEL 3
1 LAYER HEIGHT 0.1 0.25 0.3
2 INFILL PERCENTAGE 15 60 100
3 EXTRUSION
TEMPERATURE
200 230 260
18. Taguchi Statistical design in Minitab
Runs. A B C
1. 1 1 1
2. 1 2 2
3. 1 3 3
4. 2 1 2
5. 2 2 3
6. 2 3 1
7. 3 1 3
8. 3 2 1
9. 3 3 2
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To find the optimal levels of the printing parameters i.e., layer height, infill
percent and extrusion temperature, we are considered 3 levels for each factor
following low, medium and high levels of the respective printing parameters as per
the specifications of the 3d printer.
We used Design of Experiments (D.O.E) for
finding the optimal parameter levels. In D.O.E,
we followed L9 Orthogonal Array from Taguchi
Design Approach and with the help of Mini Tab
Statistical Software, we found out the optimal
levels of the considered three factors.
Taguchi Design:
L9 Orthogonal Array for 3 factors with 3 levels:
In this design, Factor A is Layer Height with 3
different levels 1,2,3.Factor B is Infill Percent with
3 different levels 1,2,3.Factor C is Extrusion
Temperature with three different levels 1,2,3
columns of L9 (3^4) array: 1 2 3
20. Methodology and Experimentation
• Sample preparation
• The specimens used in this study to evaluate the mechanical properties are
modelled based on American Society for Testing and Materials ASTM D638 type I
standards for plastic tensile testing. All the specimens were printed using PLA
filaments and a Any Cubic Kobra 2 Neo 3D Printer.
ASTM D638 type I
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21. • Designing and Slicing:
• We designed the specimen in ONSHAPE CAD Software as per its standard
dimensions and sliced it in UltiMaker CURA Slicing software by varying the levels of
parameters i.e., layer height, infill density and extrusion temperature each time as
per the Taguchi L9 Orthogonal Design Approach.
• We made 9 G-codes for 9 experimental runs and printed the sample specimens.
slicing of ASTM D638 type-I in UltiMaker Cura
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22. • 3D Printing of the Specimens
3d printed specimens
assembled 3d printer
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23. • Tensile test on Universal Testing Machine(UTM)
UTM tensile testing of specimen on UTM
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25. • Surface Roughness Test using Surface
Roughness Tester
MEXTECH SRT-6200 Surface Roughness Measuring Ra for a specimen
Tester
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27. Results
• Taguchi Analysis: Ultimate Tensile Strength (MPa) versus Layer Height (mm),
Infill Percent (%), Extrusion Temperature(0C)
• Optimal Levels for Layer Height – 0.30mm, Infill Percent – 100%,
Extrusion Temperature - 2000C for improved mechanical strength.
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28. • Taguchi Analysis: Surface Roughness Ra (microns) versus Layer Height (mm),
Infill Percent (%), Extrusion Temperature(0C)
• Optimal Levels for Layer Height – 0.25mm, Infill Percent – 15%, Extrusion
Temperature - 2000C for improved Surface Quality.
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29. • Taguchi Analysis: Ultimate Tensile Strength (MPa), Average Surface Roughness Ra
(microns) versus Layer Height (mm), Infill Percent (%), Extrusion
Temperature(0C)
• Optimal Levels for Layer Height – 0.25mm, Infill Percent – 100%,
Extrusion Temperature - 2000C for nominal values of Surface Quality and Strength.
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30. Conclusion
The conclusions of our Project Work “Optimization of 3D Printing Parameters
for improving Surface Quality and Mechanical Strength” are as follows:
1. For obtaining Printed parts with high mechanical strength, the optimal levels of
the process parameters were found out as: Layer height: 0.3 mm; Infill Percent :
100% ; Extrusion Temperature : 2000C
and Infill Density is the process parameter which has more influence on the
Mechanical Strength of the printed parts.
2. For obtaining Printed parts with good surface quality i.e., lower values of Surface
Roughness, the optimal levels of the process parameters were found out as: Layer
height: 0.25 mm; Infill Percent : 15% ; Extrusion Temperature : 2000C
and Extrusion Temperature is the process parameter which has more influence on
the Surface Quality of the printed parts.
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31. 3. For obtaining printed parts with nominal values of strength and surface roughness
i.e., average values of strength and surface roughness, the optimal levels of the
processing parameters are:
Layer height: 0.25 mm; Infill Percent : 100% ; Extrusion Temperature :
2000C
and Infill Density is the process parameter which influences both Strength and
Surface Quality of the printed parts.
Through this research work, we would suggest a Full Factorial DOE
Statistical Approach for well prediction of the response for future work. For a Full
Factorial DOE, experimenting with 3 factors with 3 levels each would require 27
experimental runs which would consume more material and power but it would
give more accurate results than the Taguchi Methodology as here we only did 9
experimental runs for 3 factors with 3 levels each. It is also suggested to develop a
Regression Model following the Full factorial DOE method to predict the
Strength and Surface Roughness of the printed parts mathematically.Also, a
smaller range of Layer Height (<0.20mm) should be addressed and investigated.
This research also suggests that effectiveness of orientation angle and the effect of
Printing Speed should be included in the future research.
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