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![Figure 1. ASTM D638 Dog-Bone Test Specimen [56].](publication/331115553/figure/fig1/AS:726586131243010@1550243041321/ASTM-D638-Dog-Bone-Test-Specimen-56_Q320.jpg)
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Context 1
... raster angle had a primary influence on the modulus of toughness. This is seen most markedly when viewing Figure 3. There is a prominent difference between the modulus of toughness of all specimens built with the [45˚/−45˚] Open Journal of Organic Polymer Materials Table 3 shows that build style 1, which was fa- bricated with the cross [0˚/90˚] raster angle, had a higher mean yield strength and modulus of resilience than build style 7, which was fabricated using the crisscross [45˚/−45˚] raster angle while holding the other parameters constant. ...
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![Fig. 1. Schematic illustration of FDM printing process [11].](profile/Huda-Al-Khawaja/publication/342221758/figure/fig1/AS:1184431138193408@1659401797143/Schematic-illustration-of-FDM-printing-process-11_Q320.jpg)
![Fig. 2 Different infill patterns and densities [17].](profile/Huda-Al-Khawaja/publication/342221758/figure/fig2/AS:1184431138177024@1659401797171/Different-infill-patterns-and-densities-17_Q320.jpg)
Citations
... The mechanical properties of 3D-printed objects vary with printing parameters provided during the manufacturing process (Khan and Kumar, 2021;Samykano et al., 2019;Sriya Ambati and Ambatipudi, 2022). Various printing parameters affect the mechanical characteristics of 3D objects, including layer thickness, infill pattern, infill density, printing orientation, number of shells, extrusion temperature and raster angle (Ahn et al., 2002;Tymrak et al., 2014;Bellini and Güçeri, 2003;Markiz et al., 2020;Žarko et al., 2017;Hibbert et al., 2019;Ceretti et al., 2023). Layer thickness refers to the height of a layer and allows the building of thinner or thicker layers. ...
Purpose
The purpose of this study is to investigate how the amount of material used and printing parameters affect the mechanical and water sorption properties of acrylonitrile butadiene styrene printed parts.
Design/methodology/approach
The specimens were printed using different printing parameters such as shell number, infill pattern and printing orientation, while accounting for the amount of material used. The mechanical properties of the printed parts were then evaluated using tensile, compression and flexural tests, along with sorption tests.
Findings
The results revealed that the maximum tensile stress of 31.41 MPa was obtained when using 100% infill and a horizontal printing orientation. Similarly, the maximum flexural strength and compression of 40.5 MPa and 100.7 MPa, respectively, were obtained with 100% infill. The printing orientation was found to have a greater impact on mechanical behavior compared to the number of shells or infill patterns. Specifically, the horizontal printing orientation resulted in specimens with at least 25% greater strength compared to the vertical printing orientation. Furthermore, the relationship between the amount of material used and strength was evident in the tensile and flexural tests, which showed a close correlation between the two.
Originality/value
This study’s originality lies in its focus on optimizing the amount of material used to achieve the best strength-to-mass ratio and negligible water infiltration. The findings showed that specimens with two shells and a 60% infill density exhibited the best strength-to-mass ratio.
... The layer thickness of 0.1 mm gave higher ultimate tensile strength in 90 degrees and modulus in 0 degrees for ABS and Nylon respectively, since there is less space between nozzles and the molten material was driven out of the nozzle more often in thinner layers, the preceding layer may warm the material and aid in strong bonding [9]. Whereas bilateral printing such as + 45/-45, and 0/90 degrees raster angle of 0.3 mm thickness showed higher UTS and modulus respectively [10]. 90-degree raster-oriented part shows higher UTS followed by 0 degrees, bilateral raster orientation 0/90 and + 45/-45. ...
... Five different infill pattern types (including 100% density) were created for the tensile tests to determine the optimal infill pattern for mechanical strength. The yield strength was determined using the 0.2% offset technique, while the toughness and resilience modulus were determined by calculating the area under the stress-strain curve up to the fracture and yield points [50]. ...
This research presents a novel methodology for simulating the failure of a 3D-printed engineering design structure. Fused deposition modeling (FDM) of polyethylene terephthalate glycol (PETG)/Carbon fiber (CF) material was utilized to develop and build the structure's topology. The mechanical characteristics of PETG/CF materials were evaluated through modeling, which was quantitatively linked to the experimental results. Scanning electron microscopy (SEM) was used to evaluate the fracture surface material before and after failure testing. The actual tests and numerical studies used five different fabrication structures which were correlated with deformation, force, and failure mode. ANSYS software was used with experimental results and finite element analysis (FEA) under both dynamic and quasi-static conditions. Five 3D printed materials of PETG reinforced with short CFs of approximately 7.6 μm in a weight fraction of 20% were investigated. The overall goal was to create a cost-effective and straightforward material production technology that can retain high mechanical strength while also providing suitable flexibility. The tensile test results of the 3D-printed PETG/CF solid structural design revealed a 23% improvement in yield strength over the other conventional structures. The study illustrates how FEA of 3D printing is used to evaluate the performance of a helmet chinstrap design with different production conditions, hence possibly reducing the product design and development time.
... Compared to pure ABS and PC, the UTS of PC-ABS was 24% and 16% higher, and also, for the elastic modulus, it was 24% and 41% higher, respectively. Hibbert et al. [23] studied the effect of build parameters, including layer thickness and infill style of ABS material, on tensile properties by the design of experiment and full-factorial method. The raster angle had the most significant effect on the toughness modulus. ...
3D printing by fused filament fabrication (FFF) can produce complicated products often used for prototyping. The major challenge for this technology is the production of functional parts with suitable mechanical properties. It is possible to improve the mechanical properties of the parts produced with FFF by correctly selecting and combining the process parameters. In this research, acrylonitrile butadiene styrene plus (ABS plus) samples with three variable parameters, including infill density, layer thickness, and raster angle, were printed to evaluate the ultimate tensile strength (UTS) and fracture strain in the tensile test. The two-dimensional digital image correlation (2D-DIC) technique measured the full-field surface strain. Before starting the test, the appropriate contrast of the sample surface was ensured using a histogram. The results were validated and predicted using response surface methodology (RSM). Prediction of the results using the quadratic model reveals that the mean error obtained for UTS and fracture strain was 2.96% and 2.87%, respectively. The analysis of variance (ANOVA) was used to validate the model. Also, the effect of the individual and interaction parameters on the response was examined. The raster angle parameter, directly related to transferring the load to the sample, was recognized as the most crucial parameter affecting both responses. The optimization results to maximize UTS and fracture strain values indicate 73.42% infill density, 0.227 mm layer thickness, and 0° raster angle, leading to UTS of 34.92 MPa and fracture strain of 3.59%. Finally, the field emission scanning electron microscope (FESEM) is employed to investigate the failure mechanism in the samples.
... It has also been used in hybrid AM processes (AM with laser cutting for surface quality improvement [51], injection molding [52], shot peening [53], rotary friction welding [31], and friction stir welding for manufacturing of large parts [54]) to further expand its fields of application. The effect of the 3DP parameters on the compression performance has been studied, focusing mainly on a limited number of parameters (one to three) [48,[55][56][57][58][59][60][61][62][63][64][65][66]. Still, research indicates the importance of compressive loading and how 3D-printed parts behave under such loading [67]. ...
Acrylonitrile butadiene styrene (ABS) is a multipurpose thermoplastic and the second most popular material in material extrusion (MEX) additive manufacturing (AM). It is widely used in various types of industrial applications in the automotive sector, housing, and food processing, among others. This work investigates the effect of seven generic control parameters (orientation angle, raster deposition angle, infill density, layer thickness, nozzle temperature, printing speed, and bed temperature) on the performance and the energy consumption of 3D-printed ABS parts in compression loading. Raw material with melt extrusion was formed in a filament form for MEX 3D printing. Samples after the ASTM D695-02a standard were 3D printed, with the seven control parameters, three levels, and five replicas each (135 experiments in total). Results were analyzed with statistical modeling tools regarding the compressive and the energy consumption metrics (printing time, weight, energy printing consumption/EPC, specific printing energy/SPE, specific printing power/SPP, compression strength, compression modulus of elasticity, and toughness). The layer thickness was the most critical control parameter. Nozzle temperature and raster deposition angle were the less critical parameters. This work provides reliable information with great technological and industrial impact.
Graphical Abstract
... However, the on-edge printing condition was the best from a mechanical properties point of view because, in this situation, + 45/−45 o raster angle improved tensile load by absorbing higher amounts of energy due to the shear stress and plastic deformations. 23 It is worth noting that there were two important factors for the higher mechanical properties of on-edge tensile specimens: contour layer and heat diffusion. The higher the number of contour layers the stronger the printed specimen. ...
... Five different infill pattern types (including 100% density) were created for the tensile tests to determine the optimal infill pattern for mechanical strength. The yield strength was determined using the 0.2% offset technique, while the toughness and resilience modulus were determined by calculating the area under the stress-strain curve up to the fracture and yield points [50]. ...
This research presents a novel methodology for simulating the failure of a 3D-printed engineering design structure. Fused deposition modeling (FDM) of polyethylene terephthalate glycol (PETG)/Carbon fiber (CF) material was utilized to develop and build the structure's topology. The mechanical characteristics of PETG/CF materials were evaluated through modeling, which was quantitatively linked to the experimental results. Scanning electron microscopy (SEM) was used to evaluate the fracture surface material before and after failure testing. The actual tests and numerical studies used five different fabrication structures which were correlated with deformation, force, and failure mode. ANSYS software was used with experimental results and finite element analysis (FEA) under both dynamic and quasi-static conditions. Five 3D printed materials of PETG reinforced with short CFs of approximately 7.6 μm in a weight fraction of 20% were investigated. The overall goal was to create a cost-effective and straightforward material production technology that can retain high mechanical strength while also providing suitable flexibility. The tensile test results of the 3D-printed PETG/CF solid structural design revealed a 23% improvement in yield strength over the other conventional structures. The study illustrates how FEA of 3D printing is used to evaluate the performance of a helmet chinstrap design with different production conditions, hence possibly reducing the product design and development time.
... However, the on-edge printing condition was the best from a mechanical properties point of view because, in this situation, + 45/−45 o raster angle improved tensile load by absorbing higher amounts of energy due to the shear stress and plastic deformations. 23 It is worth noting that there were two important factors for the higher mechanical properties of on-edge tensile specimens: contour layer and heat diffusion. The higher the number of contour layers the stronger the printed specimen. ...
Fused deposition modeling is one of the additive manufacturing techniques that is used for rapid manufacturing and prototyping, in various industries. Due to the layer-wise fabrication routine in the fused deposition modeling process, the final fabricated products often show anisotropic behavior. As a result, to investigate the mechanical performance of the three-dimensional-printed parts, complex and time-consuming analyses are required. The main purpose of the current research paper is to determine whether the isotropic assumption of material using maximum tangential stress and mean stress criteria is capable of predicting the mixed-mode fracture resistance of the three-dimensional -printed parts. Here, three different building conditions are considered for fabricating tensile and fracture specimens, and various mechanical and fracture characteristics are evaluated. Finite element simulations of the test specimens are executed and the stress results are used as input for fracture prediction of the fused deposition modeling parts. Two different cases are considered for isotropic assumptions wherein the first case (case A), each fracture specimen is modeled by using its own direct mechanical properties. While in the second case (case B), the average mechanical properties are used for modeling the cracked specimens. The results showed that both maximum tangential stress and mean stress criteria can predict the fracture loads of the fused deposition modeling parts, without the need for complex and time-consuming analyses associated with fully anisotropic materials. In addition, an improvement of the predictions was observed while using case A compared to case B.
... Also, they varied the strain rate to check its influence on the tensile strength. Hibbert et al. [3] explored that tensile, yield and ultimate strength are affected by the infill densities. However, the layer thickness provides inconsistent properties over the time interval. ...
... The Grey Relational Coefficient is calculated using equation (3). The formula includes the data points from the deviation sequence responses. ...
In several engineering applications, the demand for robust yet lightweight materials have exponentially increased. Additive Manufacturing and 3D printing technology have the scope to make this possible at a fraction of the cost compared to traditional manufacturing techniques. Majority of the previous studies are focused mainly towards the printing parameters namely build orientation, infill density, and layer height etc. Also, most studies considered strength as an output response. However, when it comes to the cellular geometry and nozzle diameter, these parameters were found limited in the literature. Similarly, the combination of output responses such as stiffness, strength, toughness and resilience are found rarely in the previous studies. The current study is designed to capture the said gap in the literature with focus on cell geometry, nozzle diameter and strain rate by using the Taguchi design of experimentation and Grey Relational Analysis. Tensile test results performed on six different patterned samples under ASTM D638 standard suggest that square patterned samples perform the best under tension and retain more mechanical strength than the other five patterns. The grey relational analysis indicates that highest grey relational grade (GRG) was achieved for the larger nozzle diameter of 0.8 mm, strain rate of 5 mm per minute and square cellular geometry. It has been observed that highest contributing factor was nozzle diameter (48.99%), whereas cellular geometry was ranked second with (40.78%) as obtained from analysis of variance (ANOVA). The grey relational analysis simplified the complex 3D printing process optimization.
... This can be due to proper melting of the filament and better flow of the molten material into the empty spaces between the deposited lines and layers. Hibbert et al. [11] reported that different build directions and layer thicknesses in the FDM-ABS parts could change their mechanical properties at any strain rate in the tensile tests. For instance, a layer thickness around 0.25 mm improved the ultimate tensile strength compared to the other layer heights. ...
The current paper deals with the influence of printing speed on the tensile and fracture strength of Acrylonitrile Butadiene Styrene (ABS) specimens made by Fused Deposition Modeling (FDM) technique. Four different printing speeds of 10, 30, 50, and 70 mm/s are used to fabricate dog-bone and Semi-Circular Bending (SCB) specimens for examining the mechanical and fracture performance of FDM-ABS parts, respectively. Due to the plastic deformation in the crack tip zone of SCB specimens prior to fracture initiation, the critical value of J-integral is chosen as the fracture characterizing parameter. Therefore, elastic–plastic finite element analyses are performed to calculate the critical values of J-integral (Jc). According to the experimental results, the fabricated specimens with a printing speed of 70 mm/s shows the best performance with the maximum elongation and fracture resistance compared to the other printed specimens with different nozzle speeds. For exploring the failure mechanisms in the tensile specimens Scanning Electron Microscopy (SEM) is utilized and various failure mechanisms have been presented and discussed. These observations are then linked to the tensile and fracture properties of the studied specimens.
