Abstract

By selecting the optimal build angle, the surface roughness of rapid prototyped parts can be minimized. The objective of this study is to develop a model for estimation of surface roughness as a function of build angle and other build parameters for parts built by Fusion Deposition Modeling (FDM) machines. For that purpose, principles of the FDM technique, along with other rapid prototyping techniques, are reviewed and various standards for surface roughness measurements are introduced. Different analytical models for the estimation of surface roughness for FDM systems, which were proposed in the literature, are reviewed and reformulated in a standard format for comparison reasons. A new hybrid model is proposed for analytical estimation of the surface roughness based on experimental results and comparison of the models. In addition, Least Square Support Vector Machine (LS-SVM) is applied for an empirical estimation of the surface roughness. Robustness of the LS-SVM model is studied and its performance is compared to the hybrid model. The experimental results confirm better results for the LS-SVM model.

Highlights

  • The objective of this study is to develop a model for estimation of surface roughness for parts built with Fusion Deposition Modeling (FDM) machines

  • It is desired to study the influence of build angle and other build parameters on the surface roughness

  • The objective of this thesis was to study surface roughness of parts build by FDM machines and to develop a model to formulate surface roughness for FDM parts as a function of build parameters, including build angle θ and layer thickness t

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Summary

Introduction

The objective of this study is to develop a model for estimation of surface roughness for parts built with Fusion Deposition Modeling (FDM) machines. FDM is one of the rapid prototyping techniques. Rapid prototyping techniques are classified and their applications reviewed. CAD file preparation methods for standard rapid prototyping files (stereolithography STL files) are introduced. Different standards for surface roughness calculation and various models for surface roughness estimation of the FDM parts are reviewed. Unlike subtractive or forming processes such as lathing, milling, grinding or coining etc., in which form is shaped by material removal or plastic deformation [1], Rapid Prototyping and Layered Manufacturing (RPLM), known as Solid Freeform Fabrication, represents a class of additive manufacturing processes in which objects are constructed layer by layer, usually in terms of a sequence of parallel planner laminae.

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