Manufacturing Technology Today

M. Sreeramulu ¹, G. Arumaikkannu ¹, S. Gowri ¹

Affiliations
1 Department of Manufacturing Engineering, College of Engineering, Anna University, Chennai-25, IN

Abstract

The high degree of automation of layered manufacturing process and its ability to create geometrically complex parts to precise dimensions provide it with a unique potential for low volume production of rapid tooling and functional components. As the rapid prototyping going towards rapid manufacturing in recent days, strength becomes the main factor which affected by many process parameters. In this study, stress analysis has been done on FDM (Fused Deposition Modeling) parts mesostructure by finite element method. In this Finite Element Analysis (FEA) models were designed with different mesostructural process parameters like road width, air gap and slice thickness, on this a linear orthotropic analysis was done to know the effect of each parameter on stress distribution. FEA results were compared with experimental yield strength results and they have better agreement with experimental results in knowing the effect of each parameter on strength.

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G. Arumaikkannu ¹, S. Gowri ¹, S. Murali Krishna ¹

Affiliations
1 Department of Manufacturing Engineering, College of Engineering, Anna University, Chennai-600025, IN

Abstract

Rapid Prototyping (RP) is a class of emerging technologies in which three-dimensional parts are built directly from computer solid models without going through traditional manufacturing steps such as process planning, tool manufacturing etc. Fused Deposition Modeling (FDM), a type of Rapid Prototyping technique is a complex technology Involving many different process parameters. These parameters have great influence on the quality of parts. The porosity of a part has a great effect on the functionality of parts. In this paper a mathematical model has been developed using Response Surface Methodology (RSM) and regression analysis to predict the influence of various process parameters on the porosity of the parts produced by FDM technique. The effect of input parameters such as slice thickness, road width, and model temperature and air gap on porosity is investigated using this mathematical model. The experimental results are statistically analyzed to determine significant factors and their interactions. Conducting experiments using specific combination of the levels of the significant factors does validation. Experimental values and tests of hypothesis demonstrate that the model developed has a satisfactory goodness of fit.

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