Additive manufacturing of fused deposition modeling for carbon fiber-PLA (CF-PLA) composites: The effects of tensile and flexural properties of process parameters (original) (raw)
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Effect of FDM process parameters on mechanical properties of 3D-printed carbon fibre–PLA composite
Progress in Additive Manufacturing, 2020
This paper presents the effect of process parameters of the fused deposition modelling (FDM) method on mechanical properties of 3D-printed carbon fibre (CF)-reinforced polylactic acid (PLA) composite. Building direction, infill percentage, and layer height are the process variables considered for studies due to their high influencing factor in mechanical properties of product. Tensile strength and impact strength are the response parameters considered in the study. Multi-optimisation is done using TOPSIS (Technique for Order Preferences by Similarity to Ideal Solution) analysis to find the best set of parameters that would provide the maximum strength using minimum material. The material used is CF-reinforced PLA composite filament (1.75-mm diameter) for 3D printing.
Mechanical characterization of FDM 3D printing of continuous carbon fiber reinforced PLA composites
Composites Part B: Engineering, 2019
Additive manufacturing of fiber reinforced composites is of great interest in various industrial applications. In this study, an innovative extruder is designed and manufactured for fused deposition modeling (FDM) 3D printers in order to produce continuous fiber reinforced thermoplastic (CFRT) composites. There are some challenges along this way such as making tension in fiber, fiber surface preparation, printing temperature and feed rate to produce a composite part with good quality. These challenges are discussed in detail. The main advantage of this extruder is that it can be mounted on the available FDM 3D printers and consequently there is no need to design a new chassis. In order to assess the quality of products, standard tensile and three-point bending specimens made of pure poly lactic acid (PLA) and carbon fiber reinforced PLA are printed and tested under quasi-static loading. Experimental results show significant improvements of tensile and bending properties of PLA. Morphological analysis is also conducted to study the bonding between the carbon fiber and PLA.
Carbon fiber-reinforced plastic composites have been intensively used for many applications due to their attractive properties. The increasing demand of carbon fiber-reinforced plastic composites is driving novel manufacturing processes to be in short manufacturing cycle time and low production cost, which is difficult to realize during carbon fiber-reinforced plastic composites fabrication in common molding processes. Fused deposition modeling, as one of the additive manufacturing techniques, has been reported for fabricating carbon fiber-reinforced plastic composites. The process parameters used in fused deposition modeling of carbon fiber-reinforced plastic composites follow those in fused deposition modeling of pure plastic materials. After adding fiber reinforcements, it is crucial to investigate proper fused deposition modeling process parameters to ensure the quality of the carbon fiber-reinforced plastic parts fabricated by fused deposition modeling. However, there are no reported investigations on the effects of fused deposition modeling process parameters on the mechanical properties of carbon fiber-reinforced plastic composites. In the experimental investigations of this paper, carbon fiber-reinforced plastic composite parts are fabricated using a fused deposition modeling machine. Tensile tests are conducted to obtain the tensile properties. The effects of fused deposition modeling process parameters on the tensile properties of fused deposition modeling-fabricated carbon fiber-reinforced plastic composite parts are investigated. The fracture interfaces of the parts after tensile testing are observed by a scanning electron microscope to explain material failure modes and reasons.
IOS Press eBooks, 2022
Lately, analysts and researchers are dealing with issues regarding natural unevenness and a worldwide temperature alteration inferable from various utilization of composite materials arranged by manufactured strands and petrochemical polymers. Subsequently, a rising consideration has been dedicated to the innovative work of polymer composites supported with the normal filaments. The normal strands are the most reasonable option of engineered filaments because of their biodegradability, eco-benevolence and mechanical properties. The normal strands are drawing in the specialists and researchers to take advantage of their properties by amalgamating them with the polymer. The properties of normal fiber built up polymer composites basically rely on different factors, for example, properties of filaments and lattices, fiber stacking rate, size and direction of strands, stacking groupings, level of interfacial holding, fiber surface medicines, hybridization and fuse of added substances and coupling specialists. Elastic and flexural tests are the main examinations to foresee the uses of the materials. A lot of exploration has been done of flexural properties of regular fiber supported polymer. In this paper, a survey on weakness and flexural properties of regular fiber supported polymer as far as impacts of fiber process parameter like Layer thickness, Infill density, Extrusion temperature, print speed using 3-D printer and process of fused deposition modelling (FDM). So, Analysis of data we have used Taguchi Analysis and compared with ANN (Artificial Neural Networks). Additionally, late utilizations of regular fiber supported polymer are likewise introduced in this review.
International Journal of Automotive and Mechanical Engineering
Additive manufacturing is gaining popularity nowadays due to its applications in the automotive, medical, aerospace industries, and sports to manufacture complex parts. Fused deposition modelling is an additive manufacturing process utilised widely due to its lower cost, fast prototyping and faster production time. The present study focuses on applying FDM to the composite material filament and the impact of parameters of FDM on the part quality. A composite filament material was prepared to combine PLA (Poly-lactic Acid) and banana fibre. Specimens were prepared using this composite filament by varying various parameters such as layer thickness, infiltration and build orientation. Flexural and tensile tests were performed as per standards. It was found that the material properties considered are significantly affected by percentage infill and build orientation. The ‘on edge’ build orientation provides better material properties as compared to the other two orientations. The tensile...
IOS Press eBooks, 2022
Additive Manufacturing (AM) is an advanced manufacturing process which reduces the physical involvement of human beings for producing products. All we required is to make a three-dimensional CAD module and feed it to a threedimensional printer. During its beginning it was just used to make a prototype, as more research has been taking place to improve its ability to make a good product due to which now it is able to produce the final product. Whenever we think about producing a product using additive manufacturing it is necessary to wisely choose the right material, right AM technique and their process parameters which fulfill the requirements. In this paper we are reviewing the process parameters of the most popularly used AM technique that is Fused Deposition Modeling (FDM) and their effect on tensile and wear strength of the printed specimen. For our study we are majorly focused on PLA and Carbon PLA as PLA is mostly use and environment friendly.
Effect of Process Parameters on Dimensional Accuracy and Tensile Strength of FDM Printed Parts
DAAAM Proceedings, 2020
Fused Deposition Modeling (FDM) is one of the most popular additive manufacturing technologies for various engineering applications. Due to the mechanism of building of products on the principle of adding layer by layer, the mechanical characteristics and quality of the product directly depend on the values of process parameters. Therefore, in this paper, test tubes for mechanical properties testing and model samples for dimensional testing were made using FDM technology. Two different polymeric materials, PLA and PC, were used to make the tubes and models. During the production of test tubes and models, three more influential process parameters varied on three levels: printing temperature, infill density and layer height. The test tubes were printed and tensile tested according to the ISO 527-2 standard. Dimensional measurements were performed on the made samples of models for dimensional tests, and dimensional deviations of the finished product in relation to the designed dimensions of the 3D model were analyzed, deviations from the shape, as well as the presence of surface defects and irregularities. At the end of the paper, recommendations are given which combination of process parameters gives for both analyzed materials better mechanical characteristics and smaller dimensional deviations of the product in the manufacture of FDM technology.
Polymers, 2022
Fused Deposition Modelling (FDM) is an actively growing additive manufacturing (AM) technology due to its ability to produce complex shapes in a short time. AM, also known as 3-dimensional printing (3DP), creates the desired shape by adding material, preferably by layering contoured layers on top of each other. The need for low cost, design flexibility and automated manufacturing processes in industry has triggered the development of FDM. However, the mechanical properties of FDM printed parts are still weaker compared to conventionally manufactured products. Numerous studies and research have already been carried out to improve the mechanical properties of FDM printed parts. Reinforce polymer matrix with fiber is one of the possible solutions. Furthermore, reinforcement can enhance the thermal and electrical properties of FDM printed parts. Various types of fibers and manufacturing methods can be adopted to reinforce the polymer matrix for different desired outcomes. This review emphasizes the fiber types and fiber insertion techniques of FDM 3D printed fiber reinforcement polymer composites. A brief overview of fused deposition modelling, polymer sintering and voids formation during FDM printing is provided, followed by the basis of fiber reinforced polymer composites, type of fibers (synthetic fibers vs. natural fibers, continuous vs. discontinuous fiber) and the composites’ performance. In addition, three different manufacturing methods of fiber reinforced thermoplastics based on the timing and location of embedding the fibers, namely ‘embedding before the printing process (M1)’, ‘embedding in the nozzle (M2)’, and ‘embedding on the component (M3)’, are also briefly reviewed. The performance of the composites produced by three different methods were then discussed.
Mechanics of Additive and Advanced Manufacturing, 2019
Fused deposition modeling (FDM) represents one of the most common techniques for rapid prototyping and industrial additive manufacturing (AM). Optimizing the process parameters which significantly impact the mechanical properties is critical to achieving the ultimate final part quality sought by industry today. This work investigates the effect of different process parameters including nozzle temperature, printing speed, and print orientation on Young’s modulus, yield strength, and ultimate strength of the final part for two types of filament, namely, Poly Lactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS). Design of Experiments (DOE) is used to determine optimized values of the process parameters for each type of filaments; also, a comparison is made between the mechanical properties of the parts fabricated with the two materials. The results show that Y-axis orientation presents the best mechanical properties in PLA while X-axis orientation is the best orientation to print parts with ABS.
Lecture notes in mechanical engineering, 2020
Additive manufacturing (AM) is highly advanced manufacturing technology. Several techniques have been introduced in the area of AM based on the method of manufacturing process. Fused deposition modelling (FDM) is one of the AM manufacturing techniques developed by Mr S. Scott crump in late 1980s and designed by Stratasys in 1990. FDM is filament extrusion-based process which fabricates 3D parts from its CAD model. In FDM process, filament made using thermoplastic material is fed in liquefier head with the help of stepper motor. In liquefier head, the filament is melted to semi-liquid state. After that, this melted filament material is extruded from nozzle to deposit roads/beads for filling each layer of the part on the platform which is placed in a chamber at predetermined temperature. The machine control head transfers in X-Y plane, whereas the platform (base) transfers in Z-direction according to selected layer thickness. Several process parameters are involved with FDM, and they have significant influence on part characteristics and efficiency of production. An operator must select process parameters while pre-processing the STL file in the FDM. In this work, literature survey is performed by referring papers on some important topics like optimization and analysis of process parameters, various materials used in FDM and mechanical behaviour of FDM parts. Effect of FDM process variables (infill percentage, infill pattern, layer thickness and extrusion temperature) on mechanical properties and dimensional accuracy of PLA was studied. The Taguchi approach was used to analyse the influence of various