Parametric Effects of Fused Filament Fabrication Approach on Surface Roughness of Acrylonitrile Butadiene Styrene and Nylon-6 Polymer

Abstract

This research objective is to optimize the surface roughness of Nylon-6 (PA-6) and Acrylonitrile Butadiene Styrene (ABS) by analyzing the parametric effects of the Fused Filament Fabrication (FFF) technique of Three-Dimensional Printing (3DP) parameters. This article discusses how to optimize the surface roughness using Taguchi analysis by the S/N ratio, ANOVA, and modeling methods. The effects of ABS parameters (initial line thickness, raster width, bed temperature, build pattern, extrusion temperature, print speed, and layer thickness) and PA-6 parameters (layer thickness, print speed, extrusion temperature, and build pattern) were investigated with the average surface roughness (Ra) and root-mean-square average surface roughness (Rq) as response parameters. Validation tests revealed that Ra and Rq decreased significantly. After the optimization, the Ra-ABS and Rq-PA-6 for the fabricated optimized values were 1.75 µm and 21.37 µm, respectively. Taguchi optimization of Ra-ABS, Rq-ABS, Ra-PA-6, and Rq-PA-6 was performed to make one step forward to use them in further research and prototypes.

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

“…The SR was measured both along and cross the melt pool track, where the average of both was used for analysis and optimization, as reported in Figure 7. Among several measurement items like Ra, Rt, Rz, Rq, the arithmetic mean (Ra) was chosen for SR measurement, and its calculations is reported in equation (4) (Mushtaq et al , 2022). …”

Improvement of tensile strength of fused deposition modelling (FDM) part using artificial neural network and genetic algorithm techniques

“…Based on the review of literature, it can be concluded that even though AM technologies have been adopted in the modern industry for several years, the academic fraternity has just started conducting more studies on the influence of variations in FDM process parameters' effects on various mechanical properties of products such as tensile, compressive, flexural strengths (Almaghariz et al ., 2016; Fera et al ., 2018). In addition, the AM literature observed optimisation of process parameters (Mushtaq et al ., 2022) and material reinforcement (Statista, 2019) as two common strategies approved by most research pioneers for improvement of FDM part performance characteristics.…”

“…Further, it is clear that the most popular controllable process parameters researched were layer thickness, raster angle, infill percentage, printing speed, filling pattern, printing plane, position of the piece on the printing table surface, initial line thickness, raster width, bed temperature and extrusion temperature (Mendricky and Fris, 2020; Algarni and Ghazali, 2021; Mushtaq et al ., 2022). These were found to be highly dominant, individually and in some cases jointly, to enhance the part mechanical performance.…”

“…Moreover, the majority of studies focussed on ABS material as test specimens (Mushtaq et al ., 2022; Algarni and Ghazali, 2021; Singh et al ., 2019). However, some studies have shown the benefits of several industrial thermoplastics such as PLA (Torres et al , 2016; Song et al .…”

“…Moreover, the majority of studies focussed on ABS material as test specimens (Mushtaq et al, 2022;Algarni and Ghazali, 2021;Singh et al, 2019). However, some studies have shown the benefits of several industrial thermoplastics such as PLA (Torres et al, 2016;Song et al 2017;Benwood et al, 2018;Mendricky and Fris, 2020;Algarni and Ghazali, 2021;Napolitano et al, 2022), ULTEM (Gebisa and Lemu, 2018), PC-ABS , PC (Domingo-Espin et al, 2015) and carbon fibre reinforced plastics (Chen et al, 2020).…”