Laser cutting of 3D printed acrylonitrile butadiene styrene plates for dimensional and surface roughness optimization

Abstract

3D printing (3DP) of polymers using fused filament fabrication (FFF) is not yet massively adopted in industrial environments due to shape accuracy and surface integrity limitations. However, the FFF process combined with laser processing (hybrid manufacturing) or other precision machining processes is under investigation nowadays and is a promising combination for high quality 3DP final parts. This work investigates the effects on the dimensional accuracy and the surface roughness of process parameters, during low power CO 2 laser cutting (LC) of thin acrylonitrile butadiene styrene (ABS) plates manufactured with the FFF process. Even though LC is highly flexible and the quality of the machined surfaces is versatile, certain problems are associated with LC, such as the kerf angle formation and the surface texture quality, which need optimization in respect to the LC parameters. The full factorial design methodology is adopted, having four parameters as input, i.e., stand-off distance (SoD), raster deposition angle (RDA), laser speed (LS), and laser power (LP), and kerf geometry characteristics as output, i.e., kerf widths (upper, middle, and down; Wu, Wm, and Wd), kerf angle (KA), and average and max height surface roughness (Ra and Rt). The statistical analysis is used to investigate the relations between the input and the output parameters. Seventy-two independent experiments were utilized. The analysis of variances (ANOVA), the interaction study, and the quadratic regression models (QRM) were adapted to fit the input with the output parameters, optimize the process KA close to 0°, and minimize the Ra close to 0 μm. The optimum parameter values (7.5 mm SoD, zero RDA, 14.4 mm/s LS, and 105 W LP) are validated by seven independent experiments, which show that only the Wu and Ra predicted values are close to the actual values following the ANOVA analysis and the mean average percengtage error (MAPE) index.

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

“…In this study, the material of the power case used was PC. A wide range of thermoplastic materials [34], including acrylonitrile butadiene styrene (ABS) [35] or PC/ABS [36] can also be used to joint a 3C power case. Laser welding [37,38] can also be employed for jointing 3C power cases because it is a high speed, precise, and clean manufacturing process.…”

Application of a Robust Decision-Making Rule for Comprehensive Assessment of Laser Cutting Conditions and Performance

“…In order to better understand the underlying physical phenomena and, ultimately, increase the technological efficiency of the laser cutting technology for a given laser cutting method and workpiece (material and thickness), a number of research studies have been conducted. Numerous recent experimental investigations have focused on the analysis of the resulting kerf geometrical characteristics including kerf width [3], kerf perpendicularity [4], kerf deviation [5], kerf angle [6], dimensional accuracy [7], and dross formation [8]. The analyses of cut surface quality characteristics, such as surface roughness [1,3], striations [9], pittings [10], and boundary layer separation [11], have attracted the attention of numerous researchers.…”

Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

“…Although joining polymeric parts with FSW has been presented in the literature, Herein, the feasibility of joining 3D printed ABS parts was investigated. Although ABS has been thoroughly investigated in MEX 3D printing [35][36][37][38] and hybrid AM, combining 3D printing with laser cutting [39], no study is yet available on the feasibility and the effect of FSW on MEX 3D printed ABS. A deeper insight into the main difference between FSW on polymer-based parts produced by mainstream processes (extrusion, rolling, etc.)…”