Abstract
In fused deposition modeling (FDM) additive manufacturing process, it is often difficult to determine the actual levels of process parameters in order to achieve the best dynamic mechanical properties of FDM manufactured part. This is mainly due to the large number of FDM parameters and a high degree of interaction between the parameters affecting such properties. This requires a large number of experiments to be determined. This paper presents a study on the influence of six FDM process parameters (layer thickness, air gap, raster angle, build orientation, road width, and number of contours) on the dynamic mechanical properties of the FDM manufactured parts using the fraction factorial design. The most influential parameters were statistically obtained through the analysis of variance (ANOVA) technique, and the results indicate that the layer thickness, the air gap, and the number of contours have the largest impact on dynamic mechanical properties. The optimal parameters for maximum dynamic mechanical properties were found to be layer thickness of 0.3302 mm, air gap of 0.00 mm, raster angle of 0.0°, build orientation of 0.0°, road width of 0.4572 mm, and 10 contours. Finally, a confirmation experiment was performed using optimized levels of process parameters, which showed good fit with the estimated values.
Similar content being viewed by others
References
O.A. Mohamed, S.H. Masood, and J.L. Bhowmik, Optimization of Fused Deposition Modeling Process Parameters: A Review of Current Research and Future Prospects, Adv. Manuf., 2015, 3, p 42–53
A. Gebhardt, Understanding Additive Manufacturing: Rapid Prototyping-Rapid Tooling-Rapid Manufacturing, Carl Hanser Verlag GmbH Co KG, Munchen, 2012
K.J. Christiyan, U. Chandrasekhar, K. Venkateswarlu, A Study on the Influence of Process Parameters on the Mechanical Properties of 3D Printed ABS Composite, IOP Conf. Series: Materials Science and Engineering, Vol 114, IOP Publishing, 2016, p 012109.
A.K. Sood, R.K. Ohdar, and S.S. Mahapatra, Experimental Investigation and Empirical Modelling of FDM Process for Compressive Strength Improvement, J. Adv. Res., 2012, 3, p 81–90
G.C. Onwubolu and F. Rayegani, Characterization and Optimization of Mechanical Properties of ABS Parts Manufactured by the Fused Deposition Modelling Process, Int. J. Manuf. Eng., 2014, 2014, p 1–13
G. Percoco, F. Lavecchia, and L.M. Galantucci, Compressive Properties of FDM Rapid Prototypes Treated with a Low Cost Chemical Finishing, Res. J. Appl. Sci. Eng. Technol, 2012, 4, p 3838–3842
S.H. Masood, K. Mau, W. Song, Tensile Properties of Processed FDM Polycarbonate Material, Materials Science Forum, Trans Tech Publ, 2010, 654-656, p 2556-2559
A. Lanzotti, M. Grasso, G. Staiano, M. Martorelli, E. Pei, and R.I. Campbell, The Impact of Process Parameters on Mechanical Properties of Parts Fabricated in PLA with an Open-Source 3-D Printer, Rapid Prototyp. J., 2015, 21, p 604–617
I. Durgun and R. Ertan, Experimental Investigation of FDM Process for Improvement of Mechanical Properties and Production Cost, Rapid Prototyp. J., 2014, 20, p 228–235
F. Górski, W. Kuczko, R. Wichniarek, A. Hamrol, Computation of Mechanical Properties of Parts Manufactured by Fused Deposition Modeling Using Finite Element Method, 10th International Conference on Soft Computing Models in Industrial and Environmental Applications, Vol 368, Springer, 2015, p 403-413
Y. Zhang and K. Chou, A Parametric Study of Part Distortions in Fused Deposition Modelling Using Three-Dimensional Finite Element Analysis, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2008, 222, p 959–968
D. Impens and R. Urbanic, Assessing the Impact of Post-Processing Variables on Tensile and Compression Characteristics for 3D Printed Components, IFAC-PapersOnLine, 2015, 48, p 652–657
A. Arivazhagan, S. Masood, I. Sbarski, Dynamic mechanical analysis of FDM rapid prototyping processed polycarbonate material, Proceedings of the 69th Annual Technical Conference of the Society of Plastics Engineers (ANTEC 2011), Boston, Massachusetts, 2011, p 950-955
A. Arivazhagan and S. Masood, Dynamic Mechanical Properties of ABS Material Processed by Fused Deposition Modelling, Int. J. Eng. Res. Appl., 2012, 2, p 2009–2014
A.K. Sood, A. Equbal, V. Toppo, R. Ohdar, and S. Mahapatra, An Investigation on Sliding Wear of FDM Built Parts, CIRP J. Manuf. Sci. Technol., 2012, 5, p 48–54
S.K. Panda, S. Padhee, S. Anoop, S. Anoop Kumar, and S. Mahapatra, Optimization of Fused Deposition Modelling (FDM) Process Parameters Using Bacterial Foraging Technique, Intell. Inf. Manag., 2009, 1, p 89–97
K.P. Menard, Dynamic Mechanical Analysis: a Practical Introduction, CRC Press, Boca Raton, 2008
T.G. Mezger, The Rheology Handbook: For Users of Rotational and Oscillatory Rheometers, Vincentz Network GmbH & Co KG, Hannover, 2006
A. Seidel, Characterization and Analysis of Polymers, Wiley, Hoboken, 2008
D.C. Montgomery, Design and Analysis of Experiments, Wiley, Hoboken, 2008
R. Pannerselvam, Design and Analysis of Experiments, PHI, Learning Pvt. Ltd., New Delhi, 2012
L. Eriksson, Design of Experiments: Principles and Applications, MKS Umetrics AB, Malmo, 2008
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Mohamed, O.A., Masood, S.H., Bhowmik, J.L. et al. Effect of Process Parameters on Dynamic Mechanical Performance of FDM PC/ABS Printed Parts Through Design of Experiment. J. of Materi Eng and Perform 25, 2922–2935 (2016). https://doi.org/10.1007/s11665-016-2157-6
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-016-2157-6