RESEARCH PAPER
An Exploratory Study on the Accuracy of Parts Printed in FDM Processes from Novel Materials
More details
Hide details
1
Faculty of Mechanical Engineering and Robotics, Department of Machine Design and Technology, AGH University of Science and Technology, Al. Adama Mickiewicza 30, 30-059 Kraków, Poland
Submission date: 2019-10-25
Acceptance date: 2020-04-28
Online publication date: 2020-04-30
Publication date: 2020-03-01
Acta Mechanica et Automatica 2020;14(1):59-68
KEYWORDS
ABSTRACT
The paper describes the experiment of assessing the chosen geometric characteristics of test models with simple geometry, shaped by the FDM (fused deposition modelling) method of different materials. The influence of the material grade and the degree of infill density on the shrinkage affecting their dimensional deviations and selected surface topography parameters of printed parts was examined and compared. Three different types of materials were used to fabricate the test models, namely HDGLASS and NANOCARBON, two new fibre reinforced composites available in the market and, additionally ABS, a popular monoplastic material. An infill density ratio of 10, 50 and 90% was assumed for each material. Three specimens were made on the same printer for each infill density, which allowed to assess the repeatability of the analysed characteristics. From among many possible shapes of models, a cube was chosen as representing the simplest geometry, facilitating the measurements themselves and the interpretation of the results. New fibre-reinforced materials are more attractive in industrial applications than pure plastics (ABS) due to their mechanical properties or appearance. They are characterized by a relatively low melting point and short cooling time, after which they can return to their original geometry; however, there is a lack of detailed data on the geometric accuracy of parts made of used composite materials. The presented work was to explanatorily broaden the knowledge about the properties of composite made parts. The practical purpose of the research was that on the basis of measurements, it would be possible to indicate among the materials used that particular material whose properties and method of application would allow obtaining the best quality surface and would be the most resistant to thermal loads. An attempt was also made to explain the possible causes of the differences in the observed characteristics of the tested materials.
REFERENCES (45)
1.
Adamczak S. (2008), Surface geometric measurements – in Polish, WNT, Warszawa.
2.
Al-Hariri L. A., Leonhardt B., Nowotarski M., Magi J., Chambliss K., Venzel T., Delekar S. and Acquah S. (2016), Carbon Nanotubes and Graphene as Additives in 3D Printing. Carbon Nanotubes, Current Progress of their Polymer Composites, 221–251,
https://scholarworks.umass.edu....
3.
Alsoufi M. S., Elsayed A. E., (2018), Surface Roughness Quality and Dimensional Accuracy - A Comprehensive Analysis of 100% In-fill Printed Parts Fabricated by a Personal/Desktop Cost-Effective FDM 3D Printer, Materials Sciences and Applications, 9, 11–40.
4.
Bähr F., Westkamper E. (2018) Correlations between Influencing Parameters and Quality Properties of Components Produced by Fused Deposition Modeling, Procedia CIRP, 72, 1214–1219.
5.
Barczewski M., Chmielewska D., Sterzyński T., Andrzejewski J. (2012), The assessment of properties of nucleated isotactic polypropylene modified with silsesquioxanes – in Polish, Przetwórstwo Tworzyw, 5, 409–413.
6.
Blok L. G., Longana M. L., Yu H., Woods B. K. S. (2018), An investigation into 3D printing of fibre reinforced thermoplastic, Additive Manufacturing, 22, 176–186.
7.
Calcagnile P., Cacciatore G., Demitri C., Montagna F. and Corcione C. E. (2018), Fused Deposition Modeling 3D PrinterA Feasibility Study of Processing Polydimethylsiloxane–Sodium Carboxymethylcellulose Composites by a Low-Cost Fused Deposition Modeling 3D Printer, Materials, 11, 1578, 1–14.
8.
Dikshit V., Nagalingam A., Yap Y. L., Sing S. L., Yeong W. Y. and Wei J. (2017), Investigation of quasi-static indentation response of inkjet printed sandwich structures under various indenter geometries, Materials, 10 (3), 290, 1–18.
9.
Dudek P., Zagórski K. (2017), Cost, resources, and energy efficiency of Additive Manufacturing, E3S Web of Conferences, ISSN 2267-1242, 14, 1–8.
10.
Duo Dong Goh, Yee Ling Yap, Shweta Agarwala, and Wai Yee Yeong (2019), Recent Progress in Additive Manufacturing of Fiber Reinforced Polymer Composite, Adv. Mater. Technol., 4, WILEYVCH Weinheim, 856–863.
11.
Gołębiowski J. (2004), Polymer nanocomposites. Structure, synthesis and properties – in Polish. Przemysł Chemiczny, 83, 1, 15–20.
12.
Grzesik W. (2016), Prediction of the Functional Performance of Machined Components Based on Surface Topography: State of the Art, 25(10), 4460–4468.
13.
Guillemot G.,Bigerelle M., and Khawaja Z. (2014), 3D Parameter to Quantify the Anisotropy Measurement of Periodic Structures on Rough Surfaces, Scanning, 36, 127–133.
14.
Hashimoto F. (2016), Characteristics and Performance of surface created by various finishing methods, Procedia CIRP, 45, 1–6.
15.
Hofstätter T., Pedersen, Bue D., Tosello G., Nørgaard H. (2019), State-of-the-art of fiber-reinforced polymers in additive manufacturing technologies, Journal of Reinforced Plastics & Composites, 36(15), 1061–1073.
16.
ISO/ASTM 52900:2015, Additive manufacturing – General principles – Terminology.
17.
Kaczyński R., Wilczewska I., A. Sfiridienok (2014), Peculiarities of the wear mechanism of polymers reinforced with unidirectional carbon fibers, Friction and Wear, 35 (6), 449–454.
18.
Knoop F., Kloke A., and Schoeppner V. (2018), Quality improvement of FDM parts by parameter optimization, AIP Conference Proceedings, 190001-1–190001-5.
19.
Kumar S., Panneerselvam K. (2016), Two-body Abrasive Wear Behavior of Nylon 6 and Glass Fiber Reinforced (GFR) Nylon 6 Composite, Procedia Technology, 25 (2016) 1129–1136.
20.
Kwiatkowski D., Kwiatkowska M. (2012), Numerical analysis of volume shrinkage of polyacetal composites with glass fibre – in Polish, Przetwórstwo Tworzyw, 5, 452–455.
21.
Ligon S.C., Liska R., Stampfl J., Gurr M. and Mulhaupt R. (2017), Polymers for 3D Printing and Customized Additive Manufacturing, Chemical Review, 117, 10212−10290.
22.
Liua Z., Lei Q., Xinga S. (2019), Mechanical characteristics of wood, ceramic, metal and carbon fiber-based PLA composites fabricated by FDM, Journal of Materials Research and Technology, 8(5), 3741–3751.
23.
Loncierz D., Kajzer W. (2016), Influence of 3D printing parameters in the FDM technology on mechanical and utility properties of objects made of PLA – in Polish, Aktualne Problemy Biomechaniki, No. 10, 43–48.
24.
Mathiaa T. G., Pawlus P., Wieczorowski M. (2011), Recent trends in surface metrology, Wear, Vol. 271, No. 3–4, 494–508.
25.
Mohan N., Senthil P., Vinodh S. & Jayanth N. (2017), A review on composite materials and process parameters optimisation for the fused deposition modelling process, Virtual and Physical Prototyping, Vol. 12, No. 1, 47–59.
26.
Nuñez P. J., Rivas A., García-Plaza E., BeamudE., Sanz-Lobera A. (2015), Dimensional and surface texture characterization in Fused Deposition Modelling (FDM) with ABS plus, The Manufacturing Engineering Society International Conference MESIC 2015, Procedia Engineering,132, 856–863.
27.
Petropoulos G., Pandazaras C. N., Davim P. (2010), Surface Texture Characterization and Evaluation Related to Machining. Surface Integrity in Machining, Springer, 37–66.
28.
PN-EN ISO 25178-6 (2011), Geometrical product specifications (GPS) — Surface texture: Areal — Part 6: Classification of methods for measuring surface texture – in Polish.
29.
PN-EN ISO 286-1 (2011), Geometrical product specifications (GPS) – ISO code system for tolerances on linear sizes – Part 1: Basis of tolerances, deviations and fits – in Polish.
30.
PN-EN ISO 4287:1999/A1 (2010), Geometrical Product Specifications (GPS) - Surface texture: Profile method - Terms, definitions and surface texture parameters – in Polish.
31.
PN-EN ISO 4288 (1997), Geometrical Product Specifications (GPS) — Surface texture: Profile method — Rules and procedures for the assessment of surface texture - in Polish.
32.
Prusinowski A., Kaczyński R. (2017), Simulation of processes occurring in the extrusion head used in additive manufacturing technology, Acta Mechanica et Automatica, 11 (4), 317–321.
33.
Roberson D.A., Shemelya C. M., MacDonald E., Wicker R. B. (2015), Expanding the Applicability of FDM-type Technologies Through Materials Development, Rapid Prototyping Journal, 21 (2),137–143.
34.
Singh R., Vatsalya (2015), Evolution of 3D Surface Parameters: A Comprehensive Survey, The International Journal of Engineering and Science, 4 (2), 4–10.
35.
Spoerk M., Holzer C., Gonzalez-Gutierrez J. (2019), Material extrusion-based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage, J. Appl. Polym. SCI, DOI: 10.1002/app.48545, 1–14.
36.
Tomiċ D., Fuduriċ A., Mihaliċ T., Simuniċ N. (2017), Dimensional accuracy of prototypes made with FDM technology, Journal of Energy Technology, 2, 51–59.
37.
Triantaphyllou A., Giusca C., Macaulay G., Roerig F., Hoebel M., Leach R., Tomita B., Milne K. (2015), Surface texture measurement for additive manufacturing, Surface Topography: Metrology and Properties, 3, 1–8.
38.
Umaras E.,Tsuzuki M. S. G. (2017), Additive Manufacturing - Considerations on Geometric Accuracy and Factors of Influence, IFAC PapersOnLine, 50 (1), 14940–14945.
39.
Wang T.- M., Xi J.-U., Jin Y. (2007), A model research for prototype warp deformation in the FDM process, The International Journal of Advanced Manufacturing Technology, 33, 1087–1096.
40.
Wieczorowski M. (2013), Theoretical basis of spatial analysis of surface asperities – in Polish, Inżynieria Maszyn, 18(3), 7–34. www.formfutura.com (access 07.09.2019).
41.
www.markforged.com (access 07.09.2019).
42.
www.rp-tech.pl (access 07.09.2019).
43.
Zabala A., Blunt L., Wilson W., Aginagalde A., Gomez X. and Mondragon I. L. (2018), The use of areal surface topography characterisation in relation to fatigue performance, MATEC Web of Conferences, 165, 1–6.
44.
Zawistowski H. (2008), Basics of the theory of shaping the properties of products in the process of injection of thermoplastics – in Polish, Mechanik, 4, 274–280.
45.
Żuchowska D. (2000), Constructional polymers – in Polish, WNT, Warszawa.