Rapid prediction and optimization of the impact of printing parameters on the residual stress of FDM-ABS parts using L27 orthogonal array design and FEA

Abstract

Fused Deposition Modelling (FDM) is now one of the most widely used techniques for building complicated 3D prototypes straightforwardly from an STL model. In this process, the part is fabricated as a layer-upon-layer deposition of a filamentwire. This deposition technique has numerous benefits; however, it causes rapid heating and cooling cycles of the filamentmaterial, which introduces residual stresses in the component during the building-up process. As a result of residual stresses, warping and distortions of the componentsduring the print process are common concerns in FDM parts. In the FDM process, there are many printing parameters that affect the mechanical properties of printed parts, such as printing speed, layer thickness, printing temperature, printing orientation, and infill density. Experimentally investigating these parameters is costly and time-consuming. This work employs a numerical solution to find the correlation between the residual stress and three printing parameters: printing orientation, raster angle, and infill pattern. The results showed that the printing orientation has the most significant influence on the residual stress value. The raster angle was the second important parameter, while the infill pattern did not influence the residual stress.