Performance evaluation of FDM water works system for ABS part

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PERFORMANCE

EVALUATION

OF FD58 WATERWORKS

SYSTEM f 0 8 - ASS PART

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KOLE J UNIVERSITI TEKNOLOGI TUN HUSSEIN ONN

BORANG PENGESAHAN STATUS TESIS*

J U D U L : PERFORMANCE EVALUATION OF FDM WATERWORKS

SYSTEM FOR ABS PART

SESI P E N G A J I A N : 2 0 0 6 / 2 0 0 7

Saya, OMAR MOHD FAIZAN BIN MARWAH

( H U R U F BESAR)

mengaku membenarkan tesis (PSM/Sarjana/Dokior Falsafah)* ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Kolej Universiti Teknologi Tun Hussein Onn. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ( V )

SULIT

T E R H A D

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam A K T A RAHSIA RASMI 1972)

(Mengandungi maklumat T E R H A D yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

V

TID AK T E R H A D

( T A N D A T A N G A N PENULIS)

Alamat Tetap:

NO 1 J L N M A N G G A , T M N MAJU 86400 PT. RAJA BATU P A H A T J O H O R D A R U L T A K Z I M

Tarikh: ^f / / J - / 2 C O&

Disahkan oleh

4/

(TANDATANG'AN PENYELIA)

P.M. IR. DR. S A P A R U D I N ARIFFIN

Nama Penyelia

Tarikh: ,4//a.

C A T A T A N : * Potong yang tidak berkenaan.

** Jika tesis ini SULIT atau TERHAD, sila Iampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau T E R H A D .

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OMAR MOHD. FAIZAN B. MARWAH

A thesis submitted in fulfillment of the requirements for the award of the degree of Master of Mechanical Engineering

Faculty of Mechanical and Manufacturing Engineering Kolej Universiti Teknologi Tun Hussein Onn

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"I declared that I read this project and in my point of view this project is qualified in terms of scope and quality for purpose of awarding the

Master of Mechanical Engineering "

Signature

Supervisor

Date

If!

Assoc. Prof. Ir. Dr. Saparudin Ariffin

Z ^ / i x / a c r o C

V) Signature

Co Supervisor : Assoc. Prof. Dr. Safian Sharif

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"I declared that this thesis entitled "Performance Evaluation Of FDM Waterworks System For ABS Part" is the result of my own research except as cited in references."

Signature :

Name of Candidate

Date

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iii

To my loving wife , Elmy Johana Mohamad and sons, Muhammad Hafiy Darwis and

Muhammad Harris Haikal, my family and friends

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ACKNOWLEDGEMENT

The author would like to express his utmost appreciation and grateful to his supervisor, Assoc. Prof. Ir. Dr. Saparudin from KUiTTHO and co-supervisor Assoc. Prof. Dr. Safian from UTM, for their guidance, supervision, valuable opinion, priceless ideas along the duration of this research and the heartfelt motivation during the

downhearted moment.

Alongside, I would also like to convey my appreciation to Mr. Hambali and Mr. Kamarudin from KUTKM for them constructive support, Mr. Mokhtar Bin Abdul Hamid from Rapid Manufacturing Laboratory for his guidance, Mr. An'Amur Rahman Bin Yunos from Metrology Laboratory and Stratasys Inc. for its valuable information on Fused Deposition Modeling process. Their valuable contribution had made this study full of excitement.

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V

ABSTRACT

Fused Deposition Modeling(FDM) is one of the Rapid Prototyping(RP)

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ABSTRAK

Fused Deposition Modeling(FDM) merupakan salah satu daripada Teknologi Pembuatan Deras untuk menghasilkan prototaip plastik daripada acrylonitrile butadiene styrene(ABS) di mana terdapat pelbagai proses pembolehubah perlu dikawal yang akan memberi kesan terhadap kualiti produk. Kemampuan untuk memilih parameter yang optimum telah menjadi penting untuk memperbaiki kualiti sesuatu produk. Kajian ini dijalankan untuk mengenalpasti parameter-parameter yang memberi kesan terhadap kualiti produk untuk FDM Waterworks Soluble Support(WSS) sistem. Faktor atau respon yang memberi kesan terhadap prestasi FDM dikaji dan keadaan optimum dapat

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CONTENTS

CHAPTER SUBJECT PAGE

TITLE i DECLARATION ii

DEDICATION iii ACKNOWLEDGEMENT iv

ABSTRACT v ABSTRAK vi CONTENTS vii LIST OF FIGURES xi

LIST OF TABLES xiv LIST OF SYMBOLS & ABBREVIATIONS xv

LIST OF APPENDIXES xvii

I P R O J E C T BACKGROUND 1

1.1 Introduction 1 1.2 Background Of Problems 3

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2.2.2 Fused Deposition Modeling Process 14

2.2.3 Waterworks System 18 2.2.4 FDM Build Material 19 2.2.5 Advantages and Disadvantage of FDM 21

2.2.6 Advantages 21 2.2.7 Disadvantages 22 2.3 Product Defect Occurred In FDM 23

2.4 Process Parameter Consideration in FDM 27

2.4.1 Air Gap 27 2.4.2 Road Width 28 2.4.3 Layer Thickness 29 2.4.4 Raster Angle 29 2.4.5 Build/Raster Orientation 29

2.4.6 Tip Size 30 2.4.7 Base Oversize 30 2.5 Previous Research Based On Response Consideration 30

2.5.1 Surface Finish 31 2.5.2 Dimensional Accuracy 33

2.5.3 Built Time 35 2.5.4 Defect Analysis 37 2.6 Design Of Experiments (DOE)/Taguchi 37

2.6.1 Experimental Design 41

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Ill RESEARCH METHODOLOGY 44

3.1 Introduction 44 3.2 Overview of the Methodology 45

3.3 FDM System 48 3.3.1 Part Post Processing 50

3.4 Product Design 51 3.4.1 Pre-Processing (Converting CAD Files to STL) 52

3.5 Experimental Planning 53 3.5.1 Project Definition 54 3.5.2 Determine the Response Variables 54

3.5.2.1 Built Time 54 3.5.2.2 Surface Roughness 55

3.5.2.3 Dimensional Accuracy 56

3.5.2.4 Part Defects 58 3.5.3 Factor Level and Ranges 59

3.5.3.1 Fix Design Factor 60 3.5.4 Experimental Design 63 3.5.5 Perform The Experiment 64

IV RESULT AND DISCUSSION 66

4.1 Introduction 66 4.2 Experimental Result 67

4.3 Result Analysis Using Design Of Experiment 70

4.3.1 Surface Roughness 70 4.3.2 Dimensional Accuracy 72

4.3.3 Built Time 73 4.3.4 Defect Measurement 75

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4.6 Summary of DOE Analysis 84 4.7 Discussion on the Responses By Classical Method 85

4.7.1 Surface Roughness 85 4.7.2 Dimensional Accuracy 86

4.7.3 Built Time 88 4.7.4 Part Defects 89

4.7.4.1 Type of Defect 91 4.8 Summary of Classical Method Analysis 98

V CONCLUSION, CONTRIBUTION AND 99 RECOMMENDATIONS

5.1 Conclusion 99 5.2 Contribution of this work 101

5.3 Future Recommendation 102

REFERENCES 103

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x i

LIST OF FIGURES

FIGURES PAGE

2.1 Classification of RP system 10 2.2 The Schematic View of FDM 13 2.3 Staircase Effect in RP Parts 23 2.4 Schematic View of Layered Boundaries Produced By Layered 24

Manufacturing Process

2.5 Tessellated or Faceted Surface Model, Chordal Error 24

2.6 Some Important Process Parameter 25 2.7 Slicing as mapping from the model of the layer domains 26

2.8 Air Gap 28 2.9 A Process Model 38

2.10a RP process chain 40 2.10b Transfer of CAD to RP System 40

3.1 Experiment Flow Chart 45 3.2 Methodology Overview and Result 47

3.3 FDM Prodigy Plus 50 3.4 Water Soluble Equipment and Waterworks Soluble Concentration 51

3.5 Product Design using Unigraphics NX2 52

3.6 STL File Setting 53 3.7 Surface Roughness Measuring Set 55

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3.13 Part Orientation 61

3.14 Model Tip 61

3.15 Modeler Setup 62

3.16 Factorial Design Menu 63 4.1 Pareto Chart for Surface Roughness 71 4.2 Pareto Chart for Dimensional Accuracies 72 4.3 Pareto Chart for Built Time 74 4.4 Pareto Chart for Defect Measurement 75 4.5 Main Effect Plot for Surface Roughness 76 4.6 Main Effect Plot for Dimensional Accuracies 78 4.7 Main Effect Plot for Built Time 79 4.8 Main Effect Plot for Defect 81 4.9 Surface Roughness Variation of Each Part 85 4.10 Overall Average Surface Roughness Measurement 86 4.11 Dimensional Variation of Each Features 87 4.12 Overall Dimensional Deviation 88 4.13 Built Time of Part Development 89 4.14 Defect Frequency for Every Features 90 4.15 Total Defect Frequency of Each Part 90

4.16 Type 1 Defect 91

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4.25 Type 10 Defect 95

4.26 Type 11 Defect 96

4.27 Type 12 Defect 96

4.28 Type 13 Defect 96

4.29 Type 14 Defect 97

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TABLE PAGE

2.1 Essential Post-Processing Tasks for Different 18 RP Processes

2.2 Overall Literature Summary 43 3.1 FDM Prodigy Plus Specifications 49

3.2 Levels of Design Factors 60 3.3 Experiment Layout 64 4.1 Experimental Result For Surface Roughness 67

4.2 Experimental Result For Dimensional Accuracy 68

4.3 Experimental Result For Built Time 68 4.4 Experimental Result For Defect Measurement 69

4.5 Total Average Of Response 69 4.6 ANOVA Table For Surface Roughness 71

4.7 ANOVA Table For Dimensional Accuracies 73

4.8 ANOVA Table For Built Time 74 4.9 ANOVA Table For Defect Occurrence 75

4.10 Regression Analysis For Surface Roughness 77 4.11 Regression Analysis For Dimensional Accuracies 78

4.12 Regression Analysis For Built Time 80 4.13 Regression Analysis For Defect 81

4.14 Result Validation 83 4.15 Summary of Analysis on the Responses 98

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LIST OF SYMBOLS & ABBREVIATIONS

% Percent (im Micro Meter °C Degree Celsius 0 Diameter

ABS Acrylonitrile Butadiene Styrene ANOVA Analysis Of Variance

BASS Breakaway Support System BT Built Time

CAD Computer-Aided Design cm Centimeters

CMM Coordinate Measuring Machine DOE Design Of Experiment

DA Dimensional Accuracy DF Defect

FDM Fused Deposition Modeling LM Layered Manufacturing

LOM Laminated Object Manufacturing m Meters

mm Millimeters

RM Rapid Manufacturing RP Rapid Prototyping

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SLS Selective Laser Sintering Std. Standard

.STL Stereolithography File UG Unigraphics

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x v i i

LIST OF APPENDIXES

APPENDIX PAGE

A Engineering Drawing Of Part Experiment 108

B Printed Part Of Experiment 110 C Result Data Of Response 112 D Surface Roughness Data And Graph 117

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PROJECT BACKGROUND

1.1 Introduction

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Fused Deposition Modeling (FDM) is one of the major technique in developing rapid prototypes or models. The FDM machine builds the part by extruding a semi-molten filament through a heated nozzle in a prescribed pattern onto a platform. A second nozzle may extrude a second material usually the support material if required. When the first layer is completed, the platform move downwards by one layer thickness and the building process repeats all over again. Once completed, the build model is removed from the platform and removal of the support materials is done to obtain the final part.

Recently , there are profoundly numerous possible parameters that can affect the final quality of part using FDM. Altering the parameters will affects the character of the resulting part. Determination of the proper significant parameters and optimum condition has been a subject of research in the FDM area for a some time . Bharath, et al. (2000), found the orientation and layer thickness as a significant parameters influence to surface finish quality. Anitha, et al. (2001), concluded the layer thickness has been proved influenced to surface roughness. Azanizawati, et al.(2003), have studied optimization for build time and surface finish. They found that the layer thickness and orientation

influence to build time and orientation was the significant parameter affect to surface roughness.

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time is a major concern in RP technologies. Very few attempts (Nur Fazidah and Safian Sharif, 2003) (D.T. Pham and S.S. Demov., 2001)(S.H. Masood, et al., 2001)

(K.Thrimurthulu, et al., 2004) have been conducted to evaluate performance of FDM process which is more dominant as compared to Stereolithography(SL). Current support removal system using BSS(Breakaway Support System) where the predecessor to WSS(Waterworks Soluble Support) system that requires manual stripping of support from the part surface seems to be less efficient as compared to WSS system in

obtaining optimum part quality within FDM technology .However in WSS system there are lack of information settings and optimum parameters used on producing acceptable part quality. Research on the FDM WSS system more limited as compared to Breakaway Support System (BASS) where the WSS is the latest invention in FDM technology .

Currently, it was reported that most of FDM users use the default settings of the various of parameters and others rely on the supplier recommendation or use trial and error methods (Azanizawati, et al., 2003). These practices created waste of material and time in achieving the optimum part quality . Furthermore, there are various methods in determining significant parameters and to predict optimum condition of settings

including Adaptive Slicing, Classical Method and DOE(Design Of Experiment). A stud}' on suitable method is required .

Hence there is a need to determine and produce a new prototype model for identifying significant parameters and optimum settings within WSS system based on various design criteria of responses through a suitable method . In addition