Materials Today: Proceedings
Effect of fused deposition modelling (FDM) process parameters on tensile strength of carbon fibre PLA
Introduction
Fusion Deposition Modelling (FDM) is afilament extrusion-based process that integrates CAD system, materials science, computer numerical control, and the extrusion process to fabricate 3D parts directly from a CAD model. In the basic FDM process, a plastic filament is drawn into a liquefier head, where the filament is heated to a semi liquid state and then extruded through a nozzle to deposit roads or beads to fill each layer of the part on to a platform in a temperature-controlled chamber. The computer-controlled head moves in X–Y plane while the platform moves in the z-direction as required by the selected layer thickness. The main process parameters include slice height (layer thickness), model tip diameter, model build temperature, part fill style, part interior style, raster width, raster angle, and raster air gap. A user is required to select these parameters when pre-processing the STL file on the FDM software. Also regarding the materials to be used in a FDM process, PLA (Poly Lactic Acid) and ABS (Acrylonitrile Butadiene Styrene) are the best thermoplastic materials in terms of mechanical properties, biodegradability and visual quality of printed parts. In the present research, literature study is done on some important aspects like mechanical properties, materials used in FDM process, analysis and optimization of process parameters in FDM.
Samir Kumar et al [1] studied the effect of process parameters (layer thickness, orientation, raster angle, raster width, and air gap) on the mechanical properties viz., tensile, flexural and impact strength by ANOVA process to validate each parameter relating to the response, and also used bacterial foraging technique to suggest the theoretical combination of parameter settings to achieve good strength for all responses. Vijay et al [2] determined the optimal surface finish of a part built by varying build orientation, layer thickness and keeping other parameters constant using the FDM process. Experiments were conducted using a fractional factorial design with two levels for layer thickness and three levels for build orientation factor. The results are statistically analyzed from the graphs to determine the significant factors and their interactions. Anoop k Sood et al. [3] investigated the effect of five important parameters such as layer thickness, part build orientation, raster angle, raster width and air gap on the compressive stress of acrylonitrile butadiene styrene (ABS P400) in FDM process. They also developed a statistically validated predictive equation to find optimal parameter setting through quantum-behaved particle swarm optimization (QPSO). Compressive stress is predicted using an artificial neural network (ANN) and is compared with a predictive equation. Miquel et al. [4] studied the influence of FDM process parameters (nozzle diameter, number of contours, and raster-to-raster air gap) on the mechanical behaviour of polycarbonate under dynamic loading at specified conditions. Taguchi approach and an analysis of variance have been used in order to quantify the influence of the parameters on such mechanical behaviour. Dinesh Kumar et al. [5] optimized the FDM process parameters viz., layer thickness, air gap, raster width, contour width, and raster orientation by using ANOVA analysis and regression analysis on the results obtained from surface roughness test. The novel ABS- M30i biomedical material was used in this work. Ognjan Lužanin et al. [6] discussed the influence of layer thickness, deposition angle and infill density on the maximum flexural force in FDM processed specimens made of polylactic acid (PLA). 33 factorial experiments without replication were used with three canter points. Analysis of variance (ANOVA) is used to find the significant influence of the process parameters. Sandeep Raut et al. [7] investigated the effect of built orientation on mechanical properties and total cost of FDM parts prepared using ABS material. Based on the results and experimental analysis it is concluded that built orientation has a significant effect on the tensile, flexural and total cost of the FDM parts. Villalpando et al. [8] studied the effect of parametric internal structures for components of ABS material built by FDM. A variety of parametric structures (solid, shell, orthogonal, hexagonal, pyramid) are considered and by using the Genetic Algorithm approach an optimization model that considers the build time, material usage, surface finish, interior geometry, strength characteristics, and related parameters are presented. Nuñeza et al. [9] determined the dimensional precision, and the characterization of flatness and surface texture obtained in FDM rapid prototype with ABS-plus as the model material.
Liseli Baich et al. [10] studied the effect of infill print design on production cost-time and different mechanical properties of 3D printed ABS specimens printed as per ASTM standards by FDM process. Infill print parameters used in the study include D1 (low), D2 (high), D3 (double dense) and D4 (solid). Faujiya Afrose et al. [11] investigated the effect of part build orientation on fatigue behaviour of FDM-processed PLA material. Fatigue tests are considered and then the results are compared to find the highest ultimate tensile stress under cyclic loading conditions. Jaya Christiyan et al. [12] evaluated the Mechanical properties of ABS + hydrous magnesium silicate composite material using the FDM process. Layer thickness and printing speed are considered with three levels each. Santhakumar et al. [13] studied the effect of FDM process parameters viz., layer thickness, part build orientation, raster angle, and raster width each at three levels together on impact strength of polycarbonate material. Analysis of Variance (ANOVA) was performed to find the most influencing process parameter on Impact strength. Basavaraj et al. [14] optimized the process parameters of the FDM process using Taguchi’s L9 orthogonal array for nylon material. Layer thickness, Orientation angle and shell thickness are the process variables considered for studies. Significant process parameters were identified using ANOVA. Griffiths et al. [15] studied the effect of build parameters on processing efficiency and material performance in FDM for PLA material. Ksawery et al. [16] focused on the mechanical properties (mainly the basic tensile strength and elastic modulus) of elements printed of PETG without additions and glass-fibre reinforced PETG using the FDM method. Yah Yun Aw et al. [17] investigated the effects of printing parameters, including infill density and printing pattern on the dynamic, mechanical, and thermoelectric properties of FDM-fabricated CABS/ZnO composites. Respective tests are done to find the optimum values of the parameters. Blok et al. [18] investigated the part quality and mechanical performance of 3D printed composite parts manufactured by two different printing methods. Continuous carbon fibre/Nylon 3D printed parts are made using the Mark Forged Mark One printer and discontinuous carbon ‘microfiber’ reinforced Nylon parts are made using a standard desktop 3D printer.
It is observed from the above literature that, ABS, ABS + composites, PLA, nylon and PETG filaments are mostly used to produce parts by FDM process for testing their mechanical properties and analyzing machining response parameters. Also the process parameters like raster angle, raster width, air gap, layer thickness and build orientation are predominantly considered to study their effect on the mechanical properties as well as machining response parameters. Moreover, there is less emphasis on the study of Mechanical properties and analysis of machining response parameters of the parts produced by Carbon fibre PLA. Therefore in this work, the effect of process parameters, viz., layer thickness, extrusion temperature and infill pattern on the tensile strength of Carbon fire PLA parts produced by FDM process is studied.
Section snippets
Experimental work
Polylactic acid or Polylactide (PLA) is a biodegradable and bioactive thermoplastic aliphatic polyester derived from renewable biomass, typically from fermented plant starch such as from corn, cassava, sugarcane or sugar beet pulp. The main advantage of PLA is perhaps the low level of shrinkage and relatively low melting temperature. The former leads to a minimum level of residual stresses in the printed parts, resulting in the absence of deformation and delamination, and the latter leads to
Results and analysis
Analysis of variance (ANOVA) is an important technique for analyzing the effect of categorical factors (FDM process parameters) on a response parameter (tensile strength). As there are three process parameters and these factors are likely to interact with respect to the response parameter, a multi factor ANOVA is appropriate in this study. Both the main effects and interactions between the factors can be estimated as a part of this ANOVA test.
Conclusions
It is found from the experimental results that the 7th sample (P1T3L1) has got the highest tensile strength of 26.59 MPa. It corresponds to a layer thickness of 0.1 mm, an extrusion temperature of 225 °C and an infill pattern of cubic structure. The main effects plot reveals the same result. Moreover, the highest value of tensile strength is obtained at lowest value of layer thickness (0.1 mm). This is so because of higher bonding area between layers.
The two-way ANOVA results indicate that the
Acknowledgment
This work is partially supported by AICTE, (Ref: 20/AICTE/RIFD/RPS (POLICY-1) 14/2013-14), Government of India, Technology Bhavan, New Delhi. Dated, 2013.
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