Effect of Multiple Piezoelectric Transducer on Fused Deposition Modeling to Improve Parts Surface Finish

S. Maidin, A.S. Mohamed, S.B. Mohamed, J. H.U. Wong, S. Sivarao

Abstract


AM which embrace as a new range technology of creating and producing end user parts in term of adding material layer by layer to create solid objects from 3D CAD data. AM, in particular Fused Deposition Modeling (FDM) used (ABS) thermoplastic, have shown the most popular among the industry as its technology can print complex geometrical part without human intervention and tools. However, FDM fierce enemy, whereas the common problem of stair-stepping, which means that seam lines appear between layers and excess material if often left as a residue, cause to lead rough surface and poor quality finish. It is often desirable for an AM printed parts to have aesthetic and functional characteristic. Hence, reducing layer thickness will generally improve surface roughness, but will add to the build time for the model. As an interest to investigate the use of ultrasonic for FDM, this experiment will focus on the effect of applying multiple piezoelectric transducer on a FDM printer. This paper aims to explore the effect of using multiple piezoelectric with different frequency applied (27, 40, 50 kHz) to study the improvement made on the surface of the printed part. An ultrasonic transducer firmly attached onto the printer platform. Optical microscope with the aid of pro VIS software version 2.90 was used to measure the quality of surface roughness of samples printed with vibration in the above stated frequency. It was found that 1 piezo with 50 kHz frequency achieved an improved surface finish due to less layer thickness defect and finer layer thickness produce.

Full Text:

PDF

References


D. Pham and R. Gault, “A comparison of rapid prototyping technologies”, International Journal of Machine Tools and Manufacture, vol.38, no. 10–11, pp. 1257–1287, 1998.

S. Choi and S. Samavedam, “Modelling and optimisation of Rapid Prototyping”, Computer Industry, vol. 47, no. 1, pp. 39–53, 2000.

F. Le Bourhis, O. Kerbrat, L. Dembinski, J.-Y. Hascoet and P. Mognol “Predictive Model for Environmental Assessment in Additive Manufacturing Process,” Procedia CIRP. vol. 15, pp. 26–31, 2014.

I. Gibson, D. W. Rosen and B. Stucker, Additive Manufacturing Technologies. Additive Manufacturing Technology. Rapid Prototyping to Drect Digital. Manufacturing, New York: Springer, 2010.

B.N. Panda, M.V.A.R. Bahubalendruni and B.B. Biswal, “Comparative evaluation of optimization algorithms at training of genetic programming for tensile strength prediction of FDM processed part”, Procedia Material Science, vol. 5,pp. 2250–2257, 2014.

A.K. Sood, R.K. Ohdar and S.S. Mahapatra, “Parametric appraisal of fused deposition modelling process using the grey Taguchi method”, Journal of Engineering Manufacture, vol. 224, pp. 135–145, 2015.

T. Tawakoli and B. Azarhourshang, “Influence of ultrasonic vibrations on dry grinding of soft steel”, International Journal of Machine Tools & Manufacture, vol. 48, pp. 1585–1591, 2008.

J. Pujana, A. Rivero, A. Celaya and L.N. López de Lacalle, “Analysis of ultrasonic-assisted drilling of Ti6Al4V”, International Journal of Machine Tools & Manufacture, vol. 49, no. 6, pp. 500–508, 2009.

Y. Deepa, “Fused deposition modeling – a rapid prototyping technique for product cycle time reduction cost effectively in aerospace applications”, IOSR Journal of Mechanical and Civil Engineering. pp. 62–68, 2014.

P. Jain and A.M. Kuthe, “Feasibility study of manufacturing using rapid prototyping: FDM approach”, Procedia Engineering, vol. 63, pp. 4–11, 2013.

G.C. Onwubolu and F. Rayegani, “Characterization and optimization of mechanical properties of ABS parts manufactured by the fused deposition modelling process”, International Journal of Manufacturing Engineering, vol. 13, pp. 1-13, 2014.

A. Kantaros and D. Karalekas, “Fiber Bragg grating based investigation of residual strains in ABS parts fabricated by fused deposition modeling process”, Material Design, vol. 50, pp. 44–50, 2013.

M. Fischer and V. Schöppner. "Some investigations regarding the surface treatment of Ultem* 9085 parts manufactured with fused deposition modeling", In 24th Annual International Solid Freeform Fabrication Symposium, Austin, 2013, pp. 12-14.

A.K. Sood, R.K. Ohdar and S.S. Mahapatra, “Experimental investigation and empirical modelling of FDM process for compressive strength improvement”, Journal of Advanced Research vol. 3, no. 1, pp. 81–90, 2012.

R.I. Campbell, M. Martorelli and H.S. Lee, “Surface roughness visualisation for rapid prototyping models”, Computer-Aided Design, vol. 34, no. 10, pp. 717–725, 2002.

A. Kumar, R.K. Ohdar and S.S. Mahapatra, “Improving dimensional accuracy of Fused Deposition Modelling processed part using grey Taguchi method”, Material Design, vol. 30, no. 10, pp. 4243–4252, 2009.

L.M. Galantucci, F. Lavecchia and G. Percoco, “Quantitative analysis of a chemical treatment to reduce roughness of parts fabricated using fused deposition modeling”, CIRP Annual Manufacturig Technology, vol. 59, no. 1, pp. 247–250, 2010.

D. Ahn, J.H. Kweon, S. Kwon, J. Song and S. Lee, “Representation of surface roughness in fused deposition modeling”, Journal of Material Processing Technology, vol. 209, no. 15–16, pp. 5593–5600, 2009.

B.B. Vasudevarao, D.P. Natarajan and M. Henderson, “Sensitivity of Rp Surface Finish To Process Parameter Variation”, in Proceeding of Solid Freefrom Fabrication Symposium, University of Texas, 2000, pp. 251–258.

T. Wang “Prototype surface micro-precision in fused deposition modeling process”, Chinese Journal of Mechanical Engineering, vol. 20, no. 1, pp. 100, 2007.

Armillotta, “Assessment of surface quality on textured FDM prototypes”, Rapid Prototyping Journal, vol. 12, no. 1, pp. 35–41, 2006.

L.M. Galantucci, F. Lavecchia and G. Percoco, “Experimental study aiming to enhance the surface finish of fused deposition modeled part”, CIRP Annals - Manufacturing Technology, vol. 58, pp. 189–192, 2009.

D.E. Brehl and T.A. Dow, “Review of vibration-assisted machining”, Precision Engineering, vol. 32, no. 3, pp. 153–172, 2008.

B. Azarhoushang and J. Akbari,“Ultrasonic-assisted drilling of Inconel 738-LC”, International Journal of Machine Tools and Manufacture, vol. 47, no. 7-8, pp. 1027–1033, 2007.

Y.S. Liao, Y.C. Chen and H.M. Lin, “Feasibility study of the ultrasonic vibration assisted drilling of Inconel superalloy”, International Journal of Machine Tools and Manufacture, vol. 47, no. 12-13, pp. 1988–1996, 2013.

J.J. Yang, H. Zhang, X.Z. Deng and B.Y. Wei., “Ultrasonic lapping of hypoid gear: System design and experiments”, Mechanism and Machine Theory, vol. 65, pp. 71–78, 2013.

W.J. Kim, F. Lu, S.H. Cho, J.K. Park and M.G. Lee, “Design and optimization of ultrasonic vibration mechanism using PZT for precision laser machining”, Physics Procedia, vol. 19, pp. 258–264, 2011.

M. Nad, “Ultrasonic horn design for ultrasonic machining technologies”, Applied and Computational Mechanics, vol. 4, no. 1, pp. 79–88, 2010.

S. Maidin, M.K. Muhamad and E. Pei, “Feasibility study of ultrasonic frequency application on fdm to improve parts surface finish”, Jurnal Teknologi, vol. 77, no. 32, pp. 27–35, 2015.

S.M.K. Tabatabaei, S. Behbahani and S.M. Mirian, “Analysis of ultrasonic assisted machining (UAM) on regenerative chatter in turning”, Journal of Materials Processing Technology, vol. 213, no. 3, pp. 418–425, 2013.

R.J. Friel and R.A. Harris, “Ultrasonic additive manufacturing A hybrid production process for novel functional products”, Procedia CIRP, vol. 6, no. 1, pp. 35–40, 2013.

M.G. Nik, M.R. Movahhedy and J. Akbari, “Ultrasonic-assisted grinding of Ti6Al4V alloy”, Procedia CIRP, vol. 1, no. 1, pp. 353–358, 2012.

H. Lian, Z. Guo, Z. Huang, Y. Tang and J. Song, “Experimental research of Al6061 on ultrasonic vibration assisted micro-milling”, Procedia CIRP, vol. 6, pp. 561–564, 2013.




© Journal of Advanced Manufacturing Technology