Abstract
Selective inhibition sintering (SIS) process intends to produce near-net-shape components through sintering of specific region of powder particles. The prediction of surface quality in SIS parts is a challenging task due to its complex part building mechanism and influence of abundant process parameters. Therefore, this study investigates the key contributing parameters such as layer thickness, heater energy, heater feedrate and printer feedrate on the surface quality characteristics ( Ra, Rzand Rq) of high-density polyethylene specimens fabricated through selective inhibition sintering process. The SIS system is custom built and experiments are conducted based on four-factor, three-level Box–Behnken design. The empirical models have been developed for predicting the influence of selected parameters on surface quality. The optimal process parameters such as the layer thickness of 0.1 mm, heater energy of 28.48 J/mm2, heater feedrate of 3.25 mm/s and printer feedrate of 110 mm/min are attained using grey relational multi-criteria decision-making approach. Furthermore, response surface analysis revealed that surface quality of sintered components is influenced significantly with heater energy and heater feedrate, followed by layer thickness. The confirmation experiments based on optimal process variables validate the developed grey relational analysis strategy.
Highlights
Additive manufacturing (AM) technique is widely used to fabricate the functional parts of three-dimensional (3D) computer-aided design (CAD) models without using fixtures and moulds
response surface methodology (RSM) is a statistical approach used for modelling and optimization of process parameters.[45]
This study considers various Selective inhibition sintering (SIS) parameters such as thickness of powder layer, feedrate of heater and inhibition printer and heat energy for the experimental studies
Summary
Additive manufacturing (AM) technique is widely used to fabricate the functional parts of three-dimensional (3D) computer-aided design (CAD) models without using fixtures and moulds. Rajamani and Balasubramanian[42] fabricated the high-density polyethylene (HDPE) parts using SIS system and evaluated the mechanical strength of sintered parts using response surface approach Their results revealed that the mechanical strength of specimens is improved by increasing the heater energy and reducing the thickness of powder layer. 0.2 28.48 3.5 120 the shrinkage of sintered specimens is significantly influenced by heater energy and layer thickness It is evident from the literature that the quality and performance of AM parts can be improved through appropriate selection of process parameters. This study analyses the significance of SIS process variables such as heater energy, layer thickness, heater and printer feedrate on surface roughness characteristics of SIS-processed HDPE parts Optimization of these parameters is performed to improve surface quality. Optimal processing condition for SIS process is obtained through RSM coupled with GRA
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