Mathematical investigation on circularity error of FDM built parts

Abstract

In the era of digitization, before manufacturing a model or part, we need to make a prototype in order to gather clear information and analyze the drawbacks of the product. This quick fabrication of a model is known as Rapid Prototyping (RP). In the group of RP, Additive Manufacturing (AM) is the most advanced one due to its wide range of applications. In the AM family, the Fused Deposition Modelling’s (FDM) wide acceptance due to its simple mechanism and inexpensiveness. While fabricating a model in FDM, the ABS or PLA thermoplastic filaments are used as printing material. Then the heated extruder head extracts the filament in hot semi-molten form and then deposit it in layer by layer manner as per the CAD data received. After the completion of the prototype, the model is thoroughly checked for the drawbacks. This drawback may affect part shape, geometry and dimensional accuracy. Due to above drawbacks, issues like surface roughness, warpage and circularity are produced. Circularity is the one of the important drawback in Fused Deposition Modelling. Circularity is a circumstance where all points of a surface of revolution are equidistant from a common axis at any section perpendicular to a common axis. Circularity error can also be understood as the radial distance between minimum circumscribing circles. To overcome such issue, our research is focused on the circularity error and how to minimize it to the negligible level by implementing Design of Experiments (DOE) and analyze the same by using MATLAB R2017a. ANOVA analysis has been adopted to develop surface plots.