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A COMPARATIVE STUDY OF
VARIOUS TECHNIQUES FOR IMPROVING
SURFACE FINISH OF FDM PATTERNS
For M. Tech.
In
Mechanical Engg.
Supervisor:
Parlad Kumar
Assistant Professor
11293039
Department of Mech. Engg.
Researcher:
Tejpal Singh
Roll No.
INTRODUCTION
The term rapid prototyping (RP) refers to a class of technologies that can
automatically construct physical models from Computer-Aided Design (CAD) data. It
is also called as Desktop manufacturing.
With the development of technologies, rapid prototyping has become more
popular. RP focuses on small quantities and complex geometries, and its application
on investment casting gives designers the freedom to rapidly modify and redesign a
product without a signicant increase of the total time and cost. It also reduces the
time and labour.
Methodology of Rapid Prototyping
Prototyping technologies
Base materials
polycarbonate, nylon.
ABS, Polycarbonate.
Stereo lithography
Photosensitive resin.
3D printing
When the first layer is completed, the table is lowered so that subsequent
layers can be superimposed
In some parts, the filament is required to support the slice where no material
exists beneath to support it.
The support material is produced with a less dense filament spacing on a layer,
so it is weaker than the model material and can be broken off easily after the
part is completed.
Review of Literature
Kumar, P. et al. investigated structure for formulating a hybrid investment casting
process for industrial uses. For this purpose many controls and effects regarding to
process have been discussed to achieve the optimum mechanical and metallurgical
properties. The authors discussed the various steps of the FDM process. In addition to
this post processing of the process and factors related to properties were also
illustrated. It was concluded that this hybrid process can be used for various industrial
and biomedical applications.
Rao, A.S. et al. (2012) found experimentally the post processing techniques to
improve the surface finish of Fused deposition modelling parts. The Authors used the
chemicals through Design of Experiments and Annova technique with different
concentrations to find out the parameters regarding the surface finish. For this a
specimen was dipped in Acetone and methylethylketone chemicals to obtain optimum
results. It was concluded that in methylethylketone the initial parameters have
negligible effects as compare to Acetone.
Kumar, P. et al. (2012) discussed a review for the application of fused deposition
modelling for rapid investment casting. The authors presented information about the
using of FDM in investment casting and also collect and illustrate the data available
about the FDM materials, their properties, factors related to process, accuracy to
produce prototypes .For this difference between the investment casting and Rapid
investment
have also been described. It was found that the material with high
strength and having low diffusion temperature are suitable for making IC patterns.
Khan, F.K. et al. (2006) investigated the effect of support structure thickness and slice
layer on the model regarding its surface roughness made by FDM technique. On both
sides of the model measurement of roughness was done perpendicular to the direction
of build layer. The authors concluded that the part of the model which is adjacent to
the top layer of the support has smoother structure than to the surface without support.
Bakar et al., 2010 found the effect of three process parameters such as layer thickness,
contour width and internal raster by using FDM technique. Experiment was conducted
on model that posses a number of geometrical shapes and sizes such as holes, cubes,
cylinders which are easily machined on plastic parts. It may be concluded that the
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dimensions which are best suited for parts to be made by FDM technique is 2mm or
above. Furthermore, the authors have suggested using suitable values of contour
width and internal raster.
Galantucci, L.M. et al. (2009) explored the effect of machining parameters on the
model made by ABS material. The surface finish has been measured by using contact
and non contact type optical system. Non contact has been adopted due to its better
results. Square specimens were manufactured by using different values of input
variables. After that chemical treatment was applied using Dimethylketone and water
solution. The author concluded that the slice height and raster width are the machining
parameters which affect the surface finish as compare to the tip diameter running
either parallel or perpendicular.
Galantucci, L.M. et al. (2010) related the mechanical and surface qualities of treated
and untreated parts. In addition to this tensile and bending properties have been
discussed by taking central composite Design of experiments by taking an FDM
marine turbine blade. After that chemical
Dimethylketone and water solution. The treatment improved a surface finish and
flexural strength with minor reduction in tensile strength with no loss of mechanical
properties.
Vasudevarao, B. et al. (2000) investigated the effect of parameters such as layer
thickness, road width, air gap and model temperature on the surface of the model
made by FDM. The experiments were conducted using fractional design with two
levels for each factor. The layer thickness posses the height of stair step and the
factors road width, air gap determine the roughness value at low inclinations. The
authors concluded that layer thickness and part orientation proved to be important
factors computing the surface quality whereas the remaining parameters like model
temperature, air gap and road width did not play important role on the surface finish
of the part.
Winker, R. (2009) discussed the review of investment casting with FDM step by step
along with advantages, applications and range of costs. The author investigated that
FDM saves a lot of time and money. Strength can be increased by using ABS
material. The first consideration is that the ABS material does not expand during the
burnout cycle which causes the shell to crack and does not melt like wax. Secondly,
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McCullough, E.J. and Yadavalli, V.K. et al. (2013) discussed a variable method to
modify the surface of ABS fused deposition modeling with micro structured features
to make them water impermeable, hydrophilic and biocompatible. The author
describes an acetone sealing method that has minor effect on the surface roughness
and structural fidelity. In addition to this grafting of polyethylene glycol on the ABS
part can minimize the protein and other bimolecular adhesion and modify the surface
hydrophilicity. Moreover author also illustrates the contact angle which makes the
surface either hydrophobic or hydrophilic. It was concluded that there is a little
change in surface roughness and the contact angle.
Problem Formulation
From review of literature it has been found that in FDM, due to the extrusion of a
semi molten plastic, surfaces exhibit a rougher finish. But, the mould duplicates
whatever kind of surface condition the master pattern presents. Therefore, there is a
need to improve surface finish. But, to improve the surface finish there are a number
of methods.
whereas some methods are used after making the FDM pattern. These methods are
known as post treatment methods. The commonly used post processing methods
includes the use of Sand paper, Wax coating, Burnishing machine or Chemical
dipping. From review of literature it is found that less work has been done on the post
treatment methods and there is a need to find the best method.
Objectives
The following objectives have been set for the present study:
1. To find the suitability of different post processing methods for decreasing the
surface roughness of FDM patterns.
2. To find the most suitable method to improve the surface finishing.
Methodology
A part of industrial importance would be selected. The sample patterns for that piece
would be prepared by using an FDM machine. The surface roughness of that patterns
would be measured. Different post treatment methods would be applied to different
patterns. After that, investment casting would be done by using these patterns. The
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Introduction
Review of literature
Problem formulation
Experimentation
Analysis of results
References
1.
http://www.stratasys.com
2.
Rao, A.S., Dharap, M.S. and Ojha, D. (2012) Investigation of post processing
techniques to reduce the surface roughness of fused deposition modeled parts,
International Journal Of Mechanical Engineering And Technology, Vol. 3(3),
pp.531-544.
3.
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6.
Khan, F.K., Salleh, A.F. Sharif, S. Mohamad, Z. Rashid, Z.A. and Murad,
N.M. (2006) A preliminary study on FDM prototype surface roughness, In:
Proceeding of Malaysian Technical Universities Conference Engineering and
Technology , Kolej University Technology.
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Kumar, P., Singh, R. and Ahuja, I.P.S. (2013) A framework for developing a
hybrid investment casting process, Accept for Publication-Asian Review of
Mechanical Engineering, No. 2, Vol. 2.
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