A critical study and analysis of process parameters of selective laser sintering Rapid prototyping

Abstract

In the Rapid Prototyping process, surface finish is very critical as it affects the part quality. As Rapid Prototyping is moving towards Rapid manufacturing there is an increasing stress on obtaining good quality parts. Surface finish of Rapid Prototyping parts is becoming more and more important with more parts being used for end purposes. Good surface finish is required for better functionality and look, but also for cost reduction in terms of reducing post-processing expenditure. A critical study and analysis of process parameters behaviour has been carried out for assessing the surface quality of parts manufactured on Selective Laser Sintering Rapid Prototyping system. The principal concern of experimental work has been investigated for achieving better surface finish by which the life of parts is governed. The primary objective of study is to analyze the optimum process parameters of Selective Laser Sintering Rapid Prototyping system. The material selected for study is “Dura Form“ and experimental work was carried out on selective laser sintering rapid prototyping machine DTM Vanguard 2500. Taguchi method is used to investigate the parameters and results are improved by using signal-to-noise methods. The major process parameters selected for study were Part Orientation, Laser Power and Scan Spacing. The study and analysis depict that Part Orientation has a major effect on the surface roughness of the part produced on Rapid Prototyping Machine. It has been observed from the study that lower value of Part Orientation level I (0 degree) gives better finish and this is because of less number of layers required for manufacturing of part. It has been observed from the study of second process parameter i.e. Laser Power that the surface finish was better at 16 W. Similarly, the surface finish obtained at lower values of Scan Spacing was for better as compared to higher values of Scan Spacing. The comparative analysis of three-process parameter indicates that the effects of variation of Part Orientation and Scan Spacing parameters are more as compare to Laser Power.