Investigating the effect of fused deposition modeling processing parameters using Taguchi design of experiment method
Investigating the effect of fused deposition modeling processing parameters using Taguchi design of experiment method
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DOI：
10.1016/j.jmapro.2018.09.025
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发表时间：
2018-12-01
影响因子：
6.2
通讯作者：
Qattawi, Ala
中科院分区：
文献类型：
--
作者：
Alafaghani, Ala'aldin;Qattawi, Ala
熔融沉积成型是一种层层制造零件的附加制造技术。AM技术的最新发展正在推动FDM从快速原型制造转向快速制造。然而，事实证明，使用FDM制造最终用户功能部件是一项具有挑战性的任务，这是因为有许多工艺参数可能会影响部件的质量。使用完全析因实验设计(DOE)来研究多个工艺参数时的影响，特别是当工艺参数不是线性变化时，是具有挑战性的。此外，为了充分挖掘加工参数的精确影响，需要大量的样本集。本文利用田口的DOE方法研究了填充百分比、填充方式、层厚和挤压温度四个工艺参数对熔融成形过程的主要影响。工艺参数的影响主要体现在制造出的熔融成形零件的力学性能和尺寸精度上。感兴趣的材料是使用商用FDM3D打印机制造的聚乳酸长丝。在本工作中，我们使用Taguchi的L9阵列，它有9次运行，每次3次重复样品，因此总共使用不同的工艺参数制造了27个样品。将制作的试件与三维CAD模型进行尺寸比较，然后按照ASTM D638标准进行测试。结果表明，要获得较好的尺寸精度，需要较低的挤压温度、较小的层厚、较低的填充率和六角形的填充方式。此外，与CAD模型相比，当前的FDM制造工艺通常会生成尺寸更大的零件。另一方面，为了增加FDM零件的强度，需要更高的挤压温度、优化的层厚度、三角形填充模式和更高的填充百分比。可以通过切换到直线填充图案和增加层厚度来改善延性。
Fused Deposition Modeling (FDM) is an Additive Manufacturing (AM) technique that fabricates parts layer upon layer. The recent development of AM technologies is driving FDM from rapid prototyping to rapid manufacturing. However, building end-user functional parts using FDM proved to be a challenging task, which is due to having many processing parameters that may influence the parts' quality. It is challenging to use full factorial Design of Experiments (DOE) to investigate the influence when there are many processing parameters, especially when the processing parameters are not expected to behave linearly. In addition, to fully exploit the accurate processing parameters influence a large number of sample sets are required. In this paper, Taguchi's DOE is used to investigate the main effects of four processing parameters in the FDM process, those are the infill percentage, infill pattern, layer thickness, and extrusion temperature. The processing parameters influence is expressed in terms of the mechanical properties and dimensional accuracy of FDM parts fabricated. The material under interest is PLA filament fabricated using a commercial FDM 3D printer. In the presented work, we used Taguchi's L9 array that had 9 runs with 3 repeated specimens for each, hence a total of 27 specimens were fabricated using varying processing parameters. The dimensions of the fabricated specimens were compared with the 3D CAD model and then tested according to the ASTM D638 standard. The results showed that for generally better dimensional accuracy, a lower extrusion temperature, smaller layer thickness, lower infill percentage, and hexagonal infill pattern were required. In addition, current FDM fabrication process usually generates parts with larger dimensions as compared to the CAD model. On the other hand, to increase the strength of FDM parts, a higher extrusion temperature, an optimized layer thickness, a triangular infill pattern, and a higher infill percentage are required. Ductility can be improved by switching to rectilinear infill pattern and by increasing the layer thickness.