Experimental optimization of process parameters on mechanical properties and the layers adhesion of 3D printed parts

Abstract

Additive manufacturing by fused filament fabrication provides an innovative manufacturing process for new design vision and complex geometry components. This study aims to establish the relationships between the process parameters and the mechanical properties of 3D printed parts using Taguchi design of experiment. The proposed method also enables the study of the filling orientation effects on the cohesion of the printed layers and the overall fracture behavior. We reviewed and optimized the effects of the critical parameters of process such as the layer thickness, the temperature, the print speed, and the filling orientation on Young's modulus and tensile strength. Then the effect of raster angle on the cohesion between the printed layers, as well as the failure modes were analyzed. The results show that the layer thickness and the filling angle are more influential on the mechanical properties. An analysis of the fracture surfaces of tensile specimens was also performed and it indicated a fracture following the filling direction. Furthermore, the fill angle 0/90° shows the best adhesion between the printed layers.

Optimization of fused filament fabrication process parameters for mechanical responses of weather‐resistant polymer (acrylonitrile styrene acrylate)

“…[42,[48][49][50] The fractured cross-sectional surface's morphology suggests a shear (Figure 6A, C) and brittle mode of failure (Figure 6B, D). [51] The specimen failure modes validate the failure modes initially observed in the stress-strain curve in Figure 4A, B, with necking phenomena in the XYZ-BO and no necking phenomena in the ZXY-BO.…”

“…The statistical values of ET, LT, and (ET*LT) terms show that set values of parameter combinations majorly affect the flow behavior and thermal bonding of interlayer adhesion, which directly affect the strength of the specimen. [ 35,51,53,54 ]…”

“…The XYZ BO shows the higher tensile strength and flexural strength compared to ZXY BO, mainly due to interlayer bonding and due to large build surface area, and bonding of interlayer adhesion, which directly affect the strength of the specimen. [35,51,53,54] Considering aforementioned analysis of experimental response and the fact that the interlaminar bonding conditions are primarily influenced by the BO and secondary by ET and LT. PS also affects interlaminar bonding, but according to analysis, PS is insignificant to experimental response (FS and TS). To analyzes the influence of the ET, LT, and PS, we construct MEP plots of two categorical variables (XYZ and ZXY BO) for tensile strength and F I G U R E 9 Microscopic images of specimens of optimized parameter values flexural strength respectively.…”