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Statistical and Experimental Analysis of Process Parameters of 3D Nylon Printed Parts by Fused Deposition Modeling: Response Surface Modeling and Optimization

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Abstract

In the current study, the additive manufacturing of nylon by fused deposition modeling is conducted based on statistical analysis. Besides, the aim of this study is the influence of process parameters, namely layer thickness (0.15 mm-0.35 mm), infill percentage (15-55%), and the number of contours (2-6) on the maximum failure load, parts weight, elongation at break, and build time. The experiment approach was used to optimize process parameters based on the statistical evaluates to reach the best objective function. The minimum value of build time and maximize of the failure load were considered as objective functions. The response surface method is regarded as an optimization process parameter, and optimum conditions were studied by experimental research to evaluate efficiency. Based on the results, the layer thickness is the significant primary variable for all responses. The experimental evaluation showed that the maximum values of failure load and elongation were obtained by changing the layer thickness from the lowest to the highest. By reduction in layer thickness at the same printing speed, the cooling rate increases, which results in greater strength and less elongation. As a result, it could be concluded that by increasing the number of contour layers from 2 to 6, the maximum failure force increased 42%. Increasing the contours due to the similar effect to increasing the infill density, increases the failure force and production time, which is also confirmed by the ANOVA.

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Authors and Affiliations

  1. Faculty of Engineering, Environment and Computing, School of Mechanical, Aerospace and Automotive Engineering, Coventry University, Coventry, UK

    Mahmoud Moradi

  2. Department of Mathematics, Computer Science and Engineering, Université du Québec à Rimouski, Rimouski, Québec, Canada

    Ahmad Aminzadeh

  3. School of Mechanical Engineering, College of Engineering, University of Tehran, Tehran, Iran

    Davood Rahmatabadi

  4. Department of Mechanical Engineering, Faculty of Engineering, Malayer University, Malayer, Iran

    Seyed Alireza Rasouli

  5. Laser Materials Processing Research Center, Malayer University, Malayer, Iran

    Seyed Alireza Rasouli

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  1. Mahmoud Moradi
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Correspondence to Davood Rahmatabadi.

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This invited article is part of a special topical focus in the Journal of Materials Engineering and Performance on Additive Manufacturing. The issue was organized by Dr. William Frazier, Pilgrim Consulting, LLC; Mr. Rick Russell, NASA; Dr. Yan Lu, NIST; Dr. Brandon D. Ribic, America Makes; and Caroline Vail, NSWC Carderock.

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Moradi, M., Aminzadeh, A., Rahmatabadi, D. et al. Statistical and Experimental Analysis of Process Parameters of 3D Nylon Printed Parts by Fused Deposition Modeling: Response Surface Modeling and Optimization. J. of Materi Eng and Perform 30, 5441–5454 (2021). https://doi.org/10.1007/s11665-021-05848-4

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