Computational investigation of the influence of process parameters of 3D printed PLA material

Open Access

Year : 2024 | Volume : | : | Page : –
By

Saurabh Pachauri

Naveen Kr. Gupta

Ankit Gupta

  1. Research Scholar Department of Mechanical Engineering, GLA University, Mathura Uttar Pradesh India
  2. Professor Department of Mechanical Engineering, GLA University, Mathura, Uttar Pradesh India
  3. Associate Professor School of Engineering, Shiv Nadar IoE Deemed to be University, Gautam Buddha Nagar Delhi India

Abstract

This study uses numerical simulation to examine the relationship between critical process parameters say, feed rate, layer height, and raster angle, on residual stresses and distortions and on the achievable density of FFF prints to identify the optimal input parameter combinations for ISO 527-2 type 1A. Methods of additive manufacturing that are utilised widely used to manufacture thermoplastic parts is fused filament fabrication. High residual stresses are one of the intrinsic phenomena that limit the widespread use of FFF in industry, despite the fact that it is now a well-established additive manufacturing process. Not all of the consequences, such as residual stresses, warping, and thermal cracking, are addressed by postprocessing. The analysis of interdependencies among various process outcomes reveals crucial insights. It is observed that high feed rates and larger layer heights are correlated with an increase in residual stresses, dimensional distortions in the final printed components, and increased porosity. The most favourable results are obtained when a raster angle of 45 degrees is employed. These findings highlight the significance of careful parameter selection and process optimisation in FFF to mitigate inherent challenges and enhance printed component reliability as well as quality.

Keywords: Fused Filament Fabrication (FFF), Raster Angle, Feed Rate, Layer Hight, Residual Stress, Porosity, Warpage, Polylactic Acid

How to cite this article: Saurabh Pachauri, Naveen Kr. Gupta, Ankit Gupta. Computational investigation of the influence of process parameters of 3D printed PLA material. Journal of Polymer and Composites. 2024; ():-.
How to cite this URL: Saurabh Pachauri, Naveen Kr. Gupta, Ankit Gupta. Computational investigation of the influence of process parameters of 3D printed PLA material. Journal of Polymer and Composites. 2024; ():-. Available from: https://journals.stmjournals.com/jopc/article=2024/view=145691

Full Text PDF Download

References

  1. ISO/ASTM International, “ISO/ASTM 52900: Additive manufacturing – General principles and Terminology,” Stand., vol. 5, no. 978-84-9042-335–6, pp. 1–26, 2015.
  2. Gibson, D. Rosen, and B. Stucker, 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing. 2015. [Online]. Available: http://link.springer.com/10.1007/978-1-4939-2113-3
  3. Hai, T., Ali, M. A., Dhahad, H. A., Alizadeh, A. A., Sharma, A., Almojil, S. F., … & Wang, D. (2023). Optimal design and transient simulation next to environmental consideration of net-zero energy buildings with green hydrogen production and energy storage system. Fuel, 336, 127126.
  4. Ahmadifar, K. Benfriha, M. Shirinbayan, and A. Tcharkhtchi, “Additive Manufacturing of Polymer-Based Composites Using Fused Filament Fabrication (FFF): a Review,” Appl. Compos. Mater., vol. 28, no. 5, pp. 1335–1380, 2021, https://doi:10.1007/s10443-021-09933-8
  5. D. Goh, Y. L. Yap, H. K. J. Tan, S. L. Sing, G. L. Goh, and W. Y. Yeong, “Process–Structure– Properties in Polymer Additive Manufacturing via Material Extrusion: A Review,” Crit. Rev. Solid State Mater. Sci., vol. 45, no. 2, pp. 113–133, Mar. 2020, https://doi:10.1080/10408436.2018.1549977
  6. Sharma, A., Sharma, K., Islam, A., & Roy, D. (2020). Effect of welding parameters on automated robotic arc welding process. Materials Today: Proceedings, 26, 2363-2367.
  7. Kucewicz, P. Baranowski, J. Malachowski, A. Popławski, and P. Płatek, “Modelling, and characterization of 3D printed cellular structures,” Mater. Des., vol. 142, pp. 177–189, Mar. 2018, https://doi:10.1016/j.matdes.2018.01.028
  8. Płatek et al., Mechanical response of additive manufactured regular cellular structures in quasi-static loading conditions-part ii: numerical investigations. 2017.
  9. Sharma, A., Chaturvedi, R., Sharma, K., & Saraswat, M. (2022). Force evaluation and machining parameter optimization in milling of aluminium burr composite based on response surface method. Advances in Materials and Processing Technologies, 8(4), 4073-4094.
  10. Guessasma, S. Belhabib, and H. Nouri, “Significance of pore percolation to drive anisotropic effects of 3D printed polymers revealed with X-ray -tomography and finite element computation,” Polymer (Guildf)., vol. 81, Oct. 2015, https://doi:10.1016/j.polymer.2015.10.041
  11. Nouri, S. Guessasma, and S. Belhabib, “Structural imperfections in additive manufacturing perceived from the X-ray micro-tomography perspective,” J. Mater. Process. Technol., vol. 234, pp. 113–124, 2016, https://doi.org/10.1016/j.jmatprotec.2016.03.019
  12. Chaturvedi, R., Sharma, A., Sharma, K., & Saraswat, M. (2022). Tribological behaviour of multi-walled carbon nanotubes reinforced AA 7075 nano-composites. Advances in Materials and Processing Technologies, 8(4), 4743-4755.
  13. Vrancken, R. Wauthle, J.-P. Kruth, and J. Humbeeck, “Study of the influence of material properties on residual stress in selective laser melting,” 24th Int. SFF Symp. – An Addit. Manuf. Conf. SFF 2013, pp. 393–407, Jan. 2013.
  14. Yadroitsev, I. Yadroitsava, P. Bertrand, and I. Smurov, “Factor analysis of selective laser melting process parameters and geometrical characteristics of synthesized single tracks,” Rapid Prototyp. J., vol. 18, pp. 201–208, Apr. 2012, https://doi:10.1108/13552541211218117
  15. Liu, Z., Zhanguo, S. U., Abed, A. M., Chaturvedi, R., Feyzbaxsh, M., & Salavat, A. K. (2022). A comparative thermodynamic and exergoeconomic scrutiny of four geothermal systems with various configurations of TEG and HDH unit implementations. Applied Thermal Engineering, 216, 119094.
  16. Vrancken, R. Wauthle, J.-P. Kruth, and J. Humbeeck, “Study of the influence of material properties on residual stress in selective laser melting,” 24th Int. SFF Symp. – An Addit. Manuf. Conf. SFF 2013, pp. 393–407, Jan. 2013.
  17. Kumar, R., Pandey, A. K., Samykano, M., Mishra, Y. N., Mohan, R. V., Sharma, K., & Tyagi, V. V. (2022). Effect of surfactant on functionalized multi-walled carbon nano tubes enhanced salt hydrate phase change material. Journal of Energy Storage, 55, 105654.
  18. Thijs, F. Verhaeghe, T. Craeghs, J. Van Humbeeck, and J.-P. Kruth, “A study of the microstructural evolution during selective laser melting of Ti–6Al–4V,” Acta Mater., vol. 58, no. 9, pp. 3303–3312, 2010,https://doi.org/10.1016/j.actamat.2010.02.004.
  19. L. Campanelli, N. Contuzzi, A. Angelastro, and A. D. Ludovico, “Capabilities and

Performances of the Selective Laser Melting Process,” M. J. Er, Ed. Rijeka: Intech Open, 2010, p. Ch. 13. https://doi.org/10.5772/10432.

  1. Cao, Y., Dhahad, H. A., Sharma, K., ABo-Khalil, A. G., El-Shafay, A. S., & Ibrahim, B. F. (2022). Comparative thermoeconomic and thermodynamic analyses and optimization of an innovative solar-driven trigeneration system with carbon dioxide and nitrous oxide working fluids. Journal of Building Engineering, 45, 103486.
  2. A. Travieso-Rodriguez, R. Jerez-Mesa, J. Llumà, O. Traver-Ramos, G. Gomez-Gras, and J. J. R. Rovira, “Mechanical properties of 3D-printing polylactic acid parts subjected to bending stress and fatigue testing,” Materials (Basel)., vol. 12, no. 23, 2019, https://doi:10.3390/ma122333859.
  3. Wicaksana and T. Rachman, “Analysis of Factors Affecting Rubber Production at PT. Lonsum, Bulukumpa District, Bulukumba Regency,” Angew. Chemie Int. Ed. 6(11), 951–952., vol. 3, no. 1, pp. 10–27, 2018, [Online]. Available: https://digilibadmin.unismuh.ac.id/upload/13589-Full_Text.pdf
  4. S. Wu, D. W. Brown, M. Kumar, G. F. Gallegos, and W. E. King, “An Experimental Investigation into Additive Manufacturing-Induced Residual Stresses in 316L Stainless Steel,” Metall. Mater. Trans. A, vol. 45, no. 13, pp. 6260–6270, 2014,

https://doi:10.1007/s11661-014-2549-x.

  1. Al‐Muntaser, A. A., Pashameah, R. A., Sharma, K., Alzahrani, E., & Tarabiah, A. E. (2022). Reinforcement of structural, optical, electrical, and dielectric characteristics of CMC/PVA based on GNP/ZnO hybrid nanofiller: nanocomposites materials for energy‐storage applications. International Journal of Energy Research, 46(15), 23984-23995.
  2. Pachauri S, Gupta NK, Gupta A. Influence of 3D printing process parameters on the mechanical properties of polylactic acid (PLA) printed with fused filament fabrication: experimental and statistical analysis. International Journal on Interactive Design and Manufacturing (IJIDeM). 2023 Aug 14:1-9, https://doi.org/10.1007/s12008-023-01424-3.
Ahead of Print Open Access Original Research
Volume
Received January 6, 2024
Accepted March 4, 2024
Published May 7, 2024
Views: 8