This paper presents practice and application of Design of Experiment techniques and Genetic Algorithm in single and multi-objective optimization with low cost, robustness, and high effectiveness through 3D printing case studies. 3D printing brings many benefits for engineering design, product development, and production process. However, it faces many challenges related to parameters control. The wrong parameter setup can result in excessive time, high production cost, waste material, and low-quality printing. This study is conducted to optimize the parameter sets for 3D Fused Deposition Modelling (FDM) products. The parameter sets, i.e., layer height, infill percentage, printing temperature, printing speed with different levels are experimented and analyzed to build mathematic models. The objectives are to describe the relationship between the inputs (parameter values) and the outputs (printing quality in term of weight, printing time and tensile strength of products). Single-objective and multi-objective models according to user’s desire are constructed and studied to identify the optimal set, optimal trade-off set of parameters. Besides, an integrated method of response surface methodology and Genetic algorithm to deal with multi-objective optimization is discussed in the paper. 3D printer, testing machines, and quality tools are used for doing experiments, measurement and collecting data. Minitab and Matlab software aid for analysis and decision-making. Proposed solutions for handling multi-objective optimization through 3D Fused Deposition Modelling product printing case study are practical and can extend for other case studies.
A new conceptual design for a small-scale and low-cost plastic recycling machine is generated by combining melting part and compression process. Starting with one of the outstanding requirements is in terms of an affordable-priced machine that can perform two processes with high accuracy and capacity, some issues related to balancing among quality, capacity and cost of machine occurred during a discussion. After implementing various designing methods such as Quality Function Deployment, Reverse Engineering, Morphological Matrix and Pugh Method, an idea of final concept about using an electric oven and hydraulic system to melt down and compress plastic tile which has a dimension of 300x300x9 mm was created. The design of concept is divided into two parts which are mechanical and electrical systems. In a mechanical section, the technical drawing and simulation are made to see how machine performs under operation. Besides, we examined the forces that applied in the moulds to evaluate the strength of the system. In heating and electricity section, we chose electrical components, designed oven parameters and conducted the heating simulation on the mould. In addition, the heating and cooling time was calculated based on the principles of thermodynamics and heat transfer. Furthermore, the manufacturing plan is created to estimate the essential resources producing a certain number of heat-forming machines. In general, the machine needs to be prototyped for controlling its main function and finding practical issues. After that, some improvements could be made to enhance efficiency and increase capacity by designing an optimal mould to more heat absorb and reduce post process, calculate and design more efficient oven, create faster lock mechanism and other improvements for an automatizing machine.
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