Abstract
Three-dimensional printed plastic products developed through fused deposition modeling (FDM) endure long-term loading in most of the applications. The tensile creep behavior of such products is one of the imperative benchmarks to ensure dimensional stability under cyclic and dynamic loads. This research dealt with the optimization of the tensile creep behavior of 3D printed parts produced through fused deposition modeling (FDM) using polylactic acid (PLA) material. The geometry of creep test specimens follows the American Society for Testing and Materials (ASTM D2990) standards. Three-dimensional printing is performed on an open-source MakerBot desktop 3D printer. The Response Surface Methodology (RSM) is employed to predict the creep rate and rupture time by undertaking the layer height, infill percentage, and infill pattern type (linear, hexagonal, and diamond) as input process parameters. A total of 39 experimental runs were planned by means of a categorical central composite design. The analysis of variance (ANOVA) results revealed that the most influencing factors for creep rate were layer height, infill percentage, and infill patterns, whereas, for rupture time, infill pattern was found significant. The optimized levels obtained for both responses for hexagonal pattern were 0.1 mm layer height and 100% infill percentage. Some verification tests were performed to evaluate the effectiveness of the adopted RSM technique. The implemented research is believed to be a comprehensive guide for the additive manufacturing users to determine the optimum process parameters of FDM which influence the product creep rate and rupture time.
Highlights
With the advent of reliable polymeric materials and advanced printing techniques, additive manufacturing (AM) has emerged an indispensable pillar in the fabrication of simple to complex products [1,2,3]
fused deposition modeling (FDM) printer uses thermoplastics filaments which are fed into an extruder and subsequently melted by the heater
Equations (1)–(3) represent rupture time based on CCD design for each infill pattern are expressed in Equations (1)–(6)
Summary
With the advent of reliable polymeric materials and advanced printing techniques, additive manufacturing (AM) has emerged an indispensable pillar in the fabrication of simple to complex products [1,2,3]. [26] studied the effect of build orientation, layer thickness, raster angle, air gap, and raster width on tensile, impact, and flexural strength of FDM-printed parts. The research was focused on the creep behavior of PLA by undertaking the effect of printing orientation and layer thickness The parameters, such as infill percentage and infill pattern type, were not considered. No specific optimization technique was applied to identify the best combination of printing parameters To fill this gap, the presented research characterizes and optimizes the creep behavior (creep rate and rupture time) of FDM-printed parts under different printing parameters, such as the infill percentage, infill pattern type, and layer thickness. This work is interesting for small and medium enterprises in developing countries that are underpinned to adopt additive manufacturing by means of small-scale desktop 3D printers
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