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Influence of processing parameters on creep and recovery behavior of FDM manufactured part using definitive screening design and ANN

Omar Ahmed Mohamed (Department of Mechanical and Product Design Engineering, Swinburne University of Technology, Hawthorn, Australia)
Syed Hasan Masood (Faculty of Engineering and Industrial Sciences, Swinburne University of Technology, Hawthorn, Australia)
Jahar Lal Bhowmik (Department of Statistics, Data Science and Epidemiology, Swinburne University of Technology, Hawthorn, Australia)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 17 October 2017

677

Abstract

Purpose

The purpose of this paper is to investigate the effect of process parameters of fused deposition modelling (FDM) 3D printing process on viscoelastic responses (creep compliance and recoverable compliance) of FDM built parts using a novel experimental design technique.

Design/methodology/approach

As part of the process characterization, a recently developed class of three-level design methodology – definitive screening design (DSD) – was used in this study to fit a second-order polynomial regression model. Artificial neural network (ANN) was also used to determine the optimal process parameters to improve creep compliance and recoverable compliance. The relationship between layer thickness, air gap, raster angle, build orientation, road width, number of contours and creep performance of FDM fabricated part was thereafter established empirically. Scanning electron microscope (SEM) is used to examine and characterize the morphology of the structures for some samples.

Findings

This study found that the creep resistance of FDM-manufactured part is significantly influenced by layer thickness, air gap, raster angle and number of contours and it can be improved by optimizing the settings of the selected parameters. The relationship between FDM process parameters and creep properties was determined, with the best creep performance observed by using 0.127 mm of layer thickness, zero air gap, zero raster angle, build orientation of 17.188°, road width of 0.4572 mm and 10 contours. Finally, the result is verified by confirmation experiments. The results prove that a DSD is a very effective design in characterizing the influence of process parameters on creep properties of FDM-built part at the lowest cost.

Originality/value

The originality of this paper lies in characterizing and optimizing the effect of process parameters on creep performance of FDM manufactured part that has not been studied in all previous studies. The paper highlights, for the first time, how the application of DSD can overcome most of the limitations encountered in the conventional techniques. This study can be used as a guide to the different additive manufacturing users of various industries and the results provide a good technical database on how FDM process parameters influence the creep performance of manufactured parts.

Keywords

Citation

Mohamed, O.A., Masood, S.H. and Bhowmik, J.L. (2017), "Influence of processing parameters on creep and recovery behavior of FDM manufactured part using definitive screening design and ANN", Rapid Prototyping Journal, Vol. 23 No. 6, pp. 998-1010. https://doi.org/10.1108/RPJ-12-2015-0198

Publisher

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Emerald Publishing Limited

Copyright © 2017, Emerald Publishing Limited

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