Optimisation of subtractive rapid prototyping process parameters using response surface methodology

Abstract

Subtractive rapid prototyping machine is the most suitable tool to manufacture a polymer based prosthetic part because it is able to achieve a low surface roughness value for a complex and customised part. Many investigations have been conducted to explain the relation among the surface roughness value, the material rate removal, and the subtractive rapid prototyping process parameters. It is important to find the optimum process parameters in order to achieve the most efficient and productive process. However, none of the research found in the literature optimises the subtractive rapid prototyping process parameters in fabricating polycarbonate part. Therefore, this research aims to find the optimum process parameters to achieve the lowest arithmetic average of surface roughness value of the polycarbonate part in maximum material removal rate. In this research, the response surface methodology is implemented to optimised feed rate, step-over, and depth of cut of the subtractive rapid prototyping process. This research finds the feed rate, step-over, and depth of cut values that can be used to achieve the best result in manufacturing of polycarbonate material.