OPTIMIZATION OF ANNEALING AND 3D PRINTING PROCESS PARAMETERS OF PLA PARTS

Yıl 2024, Cilt: 8 Sayı: 2, 185 - 201, 30.08.2024

Mhd Usama Alabd , Abdurrahim Temiz

https://doi.org/10.46519/ij3dptdi.1451666

Öz

Fused Filament Fabrication (FFF) has gained significant popularity as the prevalent additive manufacturing method due to its ability to reduce production time and expenses. However, the constraints of limited dimensional precision, poor surface quality, and relatively low Ultimate Tensile Strength (UTS) hinder compliance with the stringent regulatory norms of conventional manufacturing, necessitating post-processing for enhancement. In this investigation, the response surface method was used to optimize annealing and specific printing parameters to enhance the quality of PLA parts produced by FFF. Tensile specimens were printed with varying production parameters and annealed at varying heat treatment parameters. The following parameters are specified: layer height (0.1, 0.2, and 0.3 mm), build orientation (0°, 22.5°, 45°, 67.5°, and 90°), annealing temperature (70, 90, 110, and 130 ºC), and annealing time (60, 120, 180, and 240 min). The optimization technique aimed to enhance the UTS and match the CAD dimensions while minimizing surface roughness. The RSM optimization analysis identified the optimal parameters as layer height of 0.1 mm, build orientation at 0 degrees, annealing temperature of 110 degrees, and annealing time of 180 min. The consistent achievement of high levels of agreement between estimated and experimental response values substantiates the proposed models. A composite desirability value of 0.80 was derived for the variables due to the optimization investigation.

Anahtar Kelimeler

Additive manufacturing, Annealing, Response surface method, Optimization, 3D printing.

Destekleyen Kurum

KARABUK UNIVERSITY

Proje Numarası

KBÜBAP-23-YL-149

Teşekkür

Scientific Research Projects Coordination Unit of Karabuk University provided funding for this study. KBÜBAP-23-YL-149 is the project number. We appreciate the support.

Kaynakça

• 1. Ligon, S. C., Liska, R., Stampfl, J., Gurr, M., and Mülhaupt, R., "Polymers for 3D Printing and Customized Additive Manufacturing", Chemical Reviews, Vol. 117, Issue 15, Pages 10212–10290, 2017.
• 2. Ellson, G., Carrier, X., Walton, J., Mahmood, S. F., Yang, K., Salazar, J., and Voit, W. E., "Tough thiourethane thermoplastics for fused filament fabrication", Journal of Applied Polymer Science, Vol. 135, Issue 6, Pages 1-7, 2018.
• 3. El Magri, A., El Mabrouk, K., Vaudreuil, S., Chibane, H., and Touhami, M. E., "Optimization of printing parameters for improvement of mechanical and thermal performances of 3D printed poly(ether ether ketone) parts", Journal of Applied Polymer Science, Vol. 137, Issue 37, Pages 1-14, 2020.
• 4. Floor, J., Van Deursen, B., and Tempelman, E., "Tensile strength of 3D printed materials: Review and reassessment of test parameters", Materials Testing, Vol. 60, Issue 8, Pages 679-686, 2018.
• 5. Mahmood, A., Akram, T., Chen, H., and Chen, S., "On the Evolution of Additive Manufacturing (3D/4D Printing) Technologies: Materials, Applications, and Challenges", Polymers, Vol. 135, Issue 6, Pages 1-31, 2018.
• 6. Öz, Ö., Öztürk, F. H., and Güleç, C., "Effect of fiber content and plasticizer on mechanical and joint properties of carbon fiber powder reinforced PLA manufactured by 3D printing process", Journal of Adhesion Science And Technology, Vol. 37, Issue 15, Pages 2208-2231, 2023.
• 7. Çakan, B. G., "Effects of raster angle on tensile and surface roughness properties of various FDM filaments", Journal of Mechanical Science and Technology, Vol. 35, Issue 8, Pages 3347-3353, 2021.
• 8. Eryildiz, M., "Comparison of notch fabrication methods on the impact strength of FDM-3D-printed PLA specimens", Materials Testing, Vol. 65, Issue 3, Pages 423-430, 2023.
• 9. Demir, S., Temiz, A., and Pehlivan, F., "The investigation of printing parameters effect on tensile characteristics for triply periodic minimal surface designs by TAGUCHI", Polymer Engineering & Science, Vol. 64, Issue 3, Pages 1209-1221, 2024.
• 10. Rajpurohit, S. R. and Dave, H. K., "Effect of process parameters on tensile strength of FDM printed PLA part", Rapid Prototyping Journal, Vol. 24, Issue 8, Pages 1317-1324, 2018.
• 11. Magri, A. E., El Mabrouk, K., Vaudreuil, S., and Touhami, M. E., "Mechanical properties of CF-reinforced PLA parts manufactured by fused deposition modeling", Journal of Thermoplastic Composite Materials, Vol. 34, Issue 5, Pages 581-595, 2021.
• 12. Vyavahare, S., Teraiya, S., Panghal, D., and Kumar, S., "Fused deposition modelling: a review", Rapid Prototyping Journal, Vol. 26, Issue 1, Pages 176-201, 2020.
• 13. Hua, L., Wang, X., Ding, L., Zeng, S., Liu, J., and Wu, Z., "Effects of fabrication parameters on the mechanical properties of short basalt‐fiber‐reinforced thermoplastic composites for fused deposition modeling‐based 3D printing", Polymer Composites, Vol. 44, Issue 6, Pages 3341-3357, 2023.
• 14. Vyavahare, S., Kumar, S., and Panghal, D., "Experimental study of surface roughness, dimensional accuracy and time of fabrication of parts produced by fused deposition modelling", Rapid Prototyping Journal, Vol. 26, Issue 9, Pages 1535-1554, 2020.
• 15. Chohan, J. S. and Singh, R., "Pre and post processing techniques to improve surface characteristics of FDM parts: a state of art review and future applications", Rapid Prototyping Journal, Vol. 23, Issue 3, Pages 495-513, 2017.
• 16. Syrlybayev, D., Zharylkassyn, B., Seisekulova, A., Akhmetov, M., Perveen, A., and Talamona, D., "Optimisation of Strength Properties of FDM Printed Parts—A Critical Review", Polymers, Vol. 13, Issue 10, Pages 1-35, 2021. 17. Dey, A. and Yodo, N., "A Systematic Survey of FDM Process Parameter Optimization and Their Influence on Part Characteristics", Journal of Manufacturing and Materials Processing, Vol. 3, Issue 3, Pages 1-30, 2019.
• 18. Singh, J., Goyal, K. K., Kumar, R., and Gupta, V., "Development of artificial intelligence‐based neural network prediction model for responses of additive manufactured polylactic acid parts", Polymer Composites, Vol. 43, Issue 8, Pages 5623-5639, 2022.
• 19. Huang, M., Zheng, N., Qin, Y., Tang, Z., Zhang, H., Fan, B., and Qin, L., "Description Logic Ontology-Supported Part Orientation for Fused Deposition Modelling", Processes, Vol. 10, Issue 7, Pages 1-20, 2022.
• 20. Zhiani Hervan, S., Altınkaynak, A., and Parlar, Z., "Hardness, friction and wear characteristics of 3D-printed PLA polymer", Proceedings Of The Institution Of Mechanical Engineers, Part J: Journal of Engineering Tribology, Vol. 235, Issue 8, Pages 1590-1598, 2021.
• 21. Eryildiz, M., "Effect of Build Orientation on Mechanical Behaviour and Build Time of FDM 3D-Printed PLA Parts: An Experimental Investigation", European Mechanical Science, Vol. 5, Issue 3, Pages 116-120, 2021.
• 22. Yilmaz, M. and Yilmaz, N. F., "Effects of raster angle in single- and multi-oriented layers for the production of polyetherimide (PEI/ULTEM 1010) parts with fused deposition modelling", Materials Testing, Vol. 64, Issue 11, Pages 1651-1661, 2022.
• 23. Akhoundi, B., Nabipour, M., Hajami, F., and Shakoori, D., "An Experimental Study of Nozzle Temperature and Heat Treatment (Annealing) Effects on Mechanical Properties of High‐Temperature Polylactic Acid in Fused Deposition Modeling", Polymer Engineering & Science, Vol. 60, Issue 5, Pages 979-987, 2020.
• 24. Torres, J., Abo, E., and Sugar, A. J., "Effects of annealing and acetone vapor smoothing on the tensile properties and surface roughness of FDM printed ABS components", Rapid Prototyping Journal, Vol. 29, Issue 5, Pages 921-934, 2023.
• 25. Shbanah, M., Jordanov, M., Nyikes, Z., Tóth, L., and Kovács, T. A., "The Effect of Heat Treatment on a 3D-Printed PLA Polymer’s Mechanical Properties", Polymers, Vol. 15, Issue 6, Pages 1-12, 2023.
• 26. Rane, R., Kulkarni, A., Prajapati, H., Taylor, R., Jain, A., and Chen, V., "Post-Process Effects of Isothermal Annealing and Initially Applied Static Uniaxial Loading on the Ultimate Tensile Strength of Fused Filament Fabrication Parts", Materials, Vol. 13, Issue 2, Pages 1-18, 2020.
• 27. Elkaseer, A., Schneider, S., and Scholz, S. G., "Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing", Applied Sciences, Vol. 10, Issue 8, Pages 1-18, 2020.
• 28. El Magri, A., El Mabrouk, K., Vaudreuil, S., and Ebn Touhami, M., "Experimental investigation and optimization of printing parameters of 3D printed polyphenylene sulfide through response surface methodology", Journal of Applied Polymer Science, Vol. 138, Issue 1, Pages 1-13, 2021.
• 29. Ouassil, S., El Magri, A., Vanaei, H. R., and Vaudreuil, S., "Investigating the effect of printing conditions and annealing on the porosity and tensile behavior of 3D ‐printed polyetherimide material in Z ‐direction", Journal of Applied Polymer Science, Vol. 140, Issue 4, Pages 1-16, 2023.
• 30. Tho, N. H., "Application of box-behnken, ann, and anfis techniques for identification of the optimum processing parameters for fdm 3d printing parts", Journal of Industrial Engineering and Halal Industries, Vol. 3, Issue 1, Pages 64-86, 2022.
• 31. I. ASTM, Standard Test Method for Tensile Properties of Plastics ,2022.
• 32. Hashmi, A. W., Mali, H. S., and Meena, A., "A comprehensive review on surface quality improvement methods for additively manufactured parts", Rapid Prototyping Journal, Vol. 29, Issue 3, Pages 504-557, 2023.
• 33. Temiz, A., "The Effects of Process Parameters on Tensile Characteristics and Printing Time for Masked Stereolithography Components, Analyzed Using the Response Surface Method", Journal of Materials Engineering and Performance, Vol. 1, Issue 1, Pages 1-10, 2023.
• 34. Cotabarren, I., Palla, C. A., McCue, C. T., and Hart, A. J., "An assessment of the dimensional accuracy and geometry-resolution limit of desktop stereolithography using response surface methodology", Rapid Prototyping Journal, Vol. 25, Issue 7, Pages 1169-1186, 2019.
• 35. Wang, K., Lam, F. "Quadratic RSM Models of Processing Parameters for Three-Layer Oriented Flakeboards", Wood Fiber Sci. Vol. 31, Issue 2, Pages 173-186, 1999.
• 36. Choudhary, N., Sharma, V., and Kumar, P., "Polylactic acid‐based composite using fused filament fabrication: Process optimization and biomedical application", Polymer Composites, Vol. 44, Issue 1, Pages 69-88, 2023.
• 37. Moreno, R., Carou, D., Carazo-Álvarez, D., and Gupta, M. K., "Statistical models for the mechanical properties of 3D printed external medical aids", Rapid Prototyping Journal, Vol. 27, Issue 1, Pages 176-186, 2021.
• 38. Lanzotti, A., Grasso, M., Staiano, G., and Martorelli, M., "The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer", Rapid Prototyping Journal, Vol. 21, Issue 5, Pages 604-617, 2015.
• 39. Grasso, M., Azzouz, L., Ruiz-Hincapie, P., Zarrelli, M., and Ren, G., "Effect of temperature on the mechanical properties of 3D-printed PLA tensile specimens", Rapid Prototyping Journal, Vol. 24, Issue 8, Pages 1337-1346, 2018.
• 40. Wang, S., Ma, Y., Deng, Z., Zhang, S., and Cai, J., "Effects of fused deposition modeling process parameters on tensile, dynamic mechanical properties of 3D printed polylactic acid materials", Polymer Testing, Vol. 86, Issue 1, Pages 1-8, 2020.
• 41. Frunzaverde, D., Cojocaru, V., Ciubotariu, C.-R., Miclosina, C.-O., Ardeljan, D. D., Ignat, E. F., and Marginean, G., "The Influence of the Printing Temperature and the Filament Color on the Dimensional Accuracy, Tensile Strength, and Friction Performance of FFF-Printed PLA Specimens", Polymers, Vol. 14, Issue 10, Pages 1-15, 2022.
• 42. Mushtaq, R. T., Iqbal, A., Wang, Y., Cheok, Q., and Abbas, S., "Parametric Effects of Fused Filament Fabrication Approach on Surface Roughness of Acrylonitrile Butadiene Styrene and Nylon-6 Polymer", Materials, Vol. 15, Issue 15, Pages 1-25, 2022.
• 43. Singh, J., Singh, R., and Singh, H., "Investigations for improving the surface finish of FDM based ABS replicas by chemical vapor smoothing process: a case study", Assembly Automation, Vol. 37, Issue 1, Pages 13-21, 2017.
• 44. Garg, A., Bhattacharya, A., and Batish, A., "On Surface Finish and Dimensional Accuracy of FDM Parts after Cold Vapor Treatment", Materials and Manufacturing Processes, Vol. 31, Issue 4, Pages 522-529, 2016.
• 45. Wang, S., Daelemans, L., Fiorio, R., Gou, M., D’hooge, D. R., De Clerck, K., and Cardon, L., "Improving Mechanical Properties for Extrusion-Based Additive Manufacturing of Poly(Lactic Acid) by Annealing and Blending with Poly(3-Hydroxybutyrate)", Polymers, Vol. 11, Issue 9, Pages 1-13, 2019.
• 46. Park, S.-S., Lee, Y.-S., Lee, S.-W., Repo, E., Kim, T.-H., Park, Y., and Hwang, Y., "Facile Surface Treatment of 3D-Printed PLA Filter for Enhanced Graphene Oxide Doping and Effective Removal of Cationic Dyes", Polymers, Vol. 15, Issue 2, Pages 1-19, 2023.
• 47. Novotný, F., Urbanová, V., Plutnar, J., and Pumera, M., "Preserving Fine Structure Details and Dramatically Enhancing Electron Transfer Rates in Graphene 3D-Printed Electrodes via Thermal Annealing: Toward Nitroaromatic Explosives Sensing", ACS Applied Materials & Interfaces, Vol. 11, Issue 38, Pages 35371-35375, 2019.
• 48. Cojocaru, V., Frunzaverde, D., Miclosina, C.-O., and Marginean, G., "The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication—A Review", Polymers, Vol. 14, Issue 5, Pages 1-23, 2022.