Surface Roughness Justification in Additive Manufacturing

Abstract

Recently, developing Additive Manufacturing (AM) technologies have been increased, because its advantages toward the rapid manufacturing of physical model from the CAD system. In the AM area, the designer specifies the desired surface quality on the working drawing to be considered during the building operation. The produced surface depends on the building parameters. The aim of this work is to develop new empirical models for predicting the building orientation that satisfy required surface roughness based on FDM m/c. In this study, a new 3D CAD specimen was proposed to decrease the number of experiments, measuring errors and building cost. The specimen contains the surface orientation from 0 o to 90 o with step 10 o that was built three times at three different layer thickness (0.1, 0.3, and 0.4mm). The order of the model was determined by the test of all orientations accept at 30 o and 60 o that was used for model verification. Results show the three prediction models at certain three values of layer thicknesses. The prediction of building orientation has several benefits as follows; it is very useful information for the designer before exporting STL file, the AM users can choose the process parameters without extra trails, increase the opportunity of technology to shear in Rapid Manufacturing (RM), Rapid Tooling (RT), and in medical applications.

An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

“…The geometrical structure of the surface of models made using additive manufacturing techniques is the effect of multiple factors [44][45][46][47]. The most significant ones include the printing method applied [46,48,49], the orientation of the part in the printer's build space [44,47], as well as post-processing [45,46]. Prior to surface layer condition assessment for models made by additive manufacturing techniques, it is important to develop a methodology allowing for the choice of a suitable measuring method and analysis of results [43].…”

“…A broad spectrum of studies evaluating the condition of the surface layers of parts manufactured using additive techniques have been recently published [ 42 , 43 , 44 ]. The geometrical structure of the surface of models made using additive manufacturing techniques is the effect of multiple factors [ 44 , 45 , 46 , 47 ]. The most significant ones include the printing method applied [ 46 , 48 , 49 ], the orientation of the part in the printer’s build space [ 44 , 47 ], as well as post-processing [ 45 , 46 ].…”

An Analysis of the Casting Polymer Mold Wear Manufactured Using PolyJet Method Based on the Measurement of the Surface Topography

“…The first group of publications refers to the analysis of the surface topography of research models manufactured with the use of various rapid prototyping methods [ 74 , 75 , 76 , 77 ]. In this respect, some authors analyze the influence of the position of the manufactured prototype in relation to the 3D printer’s space on the surface quality [ 78 ]. Some of the publications in the literature also relate to the analysis of surface topography of models manufactured by hybrid methods [ 79 , 80 , 81 , 82 , 83 ].…”

Topography and wettability characterization of surfaces manufactured by SLM and treated by chemical etching

“…The experimental data on surface roughness of components issued from more classic industrial processes show a high variability, going from less than 1 lm for machining [5,6] to more than 100 lm for casting [7]. In the case of the SLM, the surface exhibits a distinctive roughness, with a mean value around 15 lm [8][9][10][11]. This resulting roughness has various origins: (i) the staircase effect due to the orientation a of the surface during the manufacturing [12][13][14]; (ii) the texture created by melting bed during the process [15]; (iii) the sintered powder particles which are trapped in the neighboring of the melting bed area.…”