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Investigations on the effect of orientations on mechanical properties in fused filament fabrication parts using numerical model

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Abstract

Fused filament fabrication (FFF) is a polymer extrusion-based additive manufacturing technique. In FFF process, semi-molten material is deposited in the form of strands and hence get bonded upon solidification through the formation of “neck”. These bonds play a crucial role in deciding the mechanical properties of FFF manufactured part. Bonding between the strands are governed by thermal energy (or in other words), a heating–cooling effect needs to be considered for the evaluation of FFF part mechanical properties. These are influenced by the FFF process parameters namely, extrusion temperature, layer thickness, part orientation, and raster orientation. This study attempts to develop a new mathematical model to establish a relationship between “neck radius” and “time” at different raster orientations. This paper explains the relationship between neck growth and raster orientations in FFF process. A new mathematical model has been developed by equating the work done by the surface tension and work done due to viscous forces by the molten polymer strands. From the developed mathematical model, the neck radius is evaluated with varying raster orientation (Ø°) (0 < Ø ≤ 900). The study also involves an experimental approach to establish the fact that neck growth (in the form of strength) is influenced by the FFF parameter settings the FFF parameter settings influence neck growth (in the form of strength). A face-centered design of experiment is considered, 30 experiments are performed and analyzed for responses like tensile strength, flexural strength, and volumetric shrinkage. Analysis of variance (ANOVA) is performed to validate statistical stability the proposed model. Response surface methodology is considered to study the interaction behavior of each FFF process parameters on each response parameters. From the developed mathematical model, the absolute neck growth at 30°, 45°, 60° and 90° raster orientations are obtained as 0.35 mm, 0.29 mm, 0.30 mm and 0.13 mm, respectively. The current study indicates the inverse relationship between neck growth and raster orientation. Study shows that mechanical properties highly depend on parameters that directly influence part orientation, raster orientation, and the extrusion temperature. Present study shows that higher mechanical properties can be achieved at lower raster and part orientation which is in greater agreement with the proposed mathematical model results.

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Authors and Affiliations

  1. PDEU: Pandit Deendayal Energy University, Gandhinagar, Gujarat, India

    Achyut Trivedi & Pavan Kumar Gurrala

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  1. Achyut Trivedi
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  2. Pavan Kumar Gurrala
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Correspondence to Pavan Kumar Gurrala.

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Trivedi, A., Gurrala, P.K. Investigations on the effect of orientations on mechanical properties in fused filament fabrication parts using numerical model. J Braz. Soc. Mech. Sci. Eng. 44, 145 (2022). https://doi.org/10.1007/s40430-022-03422-0

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