Abstract
Material extrusion (ME), one of the most widely used additive manufacturing technique, has the advantages of freedom of design, wide range of raw materials, strong ability to manufacture complex products, etc. However, ME products have obvious surface defects due to the layer-by-layer manufacturing characteristics. To reveal the generation mechanism, the three-dimensional surface roughness (3DSR) of ME products was investigated theoretically and experimentally. Based on the forming process of bonding neck, the 3DSR theoretical model in two different directions (vertical and parallel to the fiber direction) was established respectively. The preparation of ME samples was then completed and a series of experimental tests were performed to determine their surface roughness with the laser microscope. Through the comparison between theoretical and experimental results, the proposed model was validated. In addition, sensitivity analysis is implemented onto the proposed model, investigating how layer thickness, extrusion temperature, and extrusion width influence the samples’ surface roughness. This study provides theoretical basis and technical insight into improving the surface quality of ME products.
Highlights
Additive manufacturing has gradually developed from the initial prototype manufacturing to direct manufacturing and mass manufacturing, which has a wide range of important application prospects [1–3]
The Surface Roughness Vertical to the Fiber Direction (SRVF)-HB theoretical model can accurately predict the surface profile of the Material extrusion (ME) sample vertical to the fiber direction based on the horizontal bonding neck
TEhsearmefpolrees, t(hRe,SiR=V1F~-3L).BItmcoandeblecaseneanctchuartatbeolythptrheedvicatluthees saunrdfatcrenpdroafireleinvegrotiocdalatgoretheme fienbte.rTdhiererecftoiorne,bthaseeSdRoVnFt-hLeBlmonogdietul cdainaalcbcounradtienlyg pnreecdki.ct the surface profile vertical to the fiber direction based on the longitudinal bonding neck
Summary
Additive manufacturing has gradually developed from the initial prototype manufacturing to direct manufacturing and mass manufacturing, which has a wide range of important application prospects [1–3]. Angelo et al [17], considering the influence of step effect on the surface profile, improved the model set up by Anh et al [18,19], and proposed a new parameter Pa (ISO 4287) for evaluating the ME products’ surface quality. Assuming that the surface profile of ME products was parabolic, Pandey et al [24] took into account the influence of layer thickness and printing direction, and created a semi-empirical formula for predicting the surface roughness of ME products. Based on the bonding neck forming process (horizontal and longitudinal bonding necks), a three-dimensional surface roughness (3DSR) theoretical model of ME products was established in this paper, with the anisotropic characteristics and temperature taken into account. Sensitivity analysis of the model was carried out to predict how extrusion width, layer thickness, and extrusion temperature influence the ME products’ surface roughness
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
