Despite recent research efforts improving Additive Manufacturing (AM) systems, quality and reliability of AM built products remains as a challenge. There is a critical need to achieve process parameters optimizing multiple mechanical properties or geometry accuracy measures simultaneously. The challenge is that the optimal value of various objectives may not be achieved concurrently. Most of the existing studies aimed to obtain the optimal process parameters for each objective individually, resulting in duplicate experiments and high costs. In this study we investigated multiple geometry accuracy measures of parts fabricated by Fused Filament Fabrication (FFF) system. An integrated framework for systematically designing experiments is proposed to achieve multiple sets of FFF process parameters resulting in optimal geometry integrity. The proposed method is validated using a real world case study. The results show that optimal properties are achieved in a more efficient manner compared with existing methods.
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Manufacturing of Soft Magnets using the Fused Filament Fabrication Process
Rare-earth (RE) materials are currently used to fabricate permanent magnets through various additive manufacturing (AM) methods. Fused filament fabrication (FFF) is one of the most commonly used polymer-based AM methods and has recently been used to produce metal-matrix composites, known as “green parts,” using a metal powder-infused filament. The FFF method has gained much attention in various industries including the automotive, aerospace, and medical fields. Therefore, involving RE in the FFF process using magnetic powder-infused filaments promises to result in the fabrication of low-cost, efficient, and complex magnetic components based on application areas. This module introduces the FFF process and provides a case study for high school and technical college students to gain a fundamental understanding of how magnetic powders are infused and how parts are fabricated using this method.
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- Award ID(s):
- 1601587
- NSF-PAR ID:
- 10299364
- Editor(s):
- Stoebe, Thomas
- Date Published:
- Journal Name:
- MatEDU Resource Center
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Despite recent research efforts improving Additive Manufacturing (AM) systems, quality and reliability of AM built products remains as a challenge. There is a critical need to achieve process parameters optimizing multiple mechanical properties or geometry accuracy measures simultaneously. The challenge is that the optimal value of various objectives may not be achieved concurrently. Most of the existing studies aimed to obtain the optimal process parameters for each objective individually, resulting in duplicate experiments and high costs. In this study we investigated multiple geometry accuracy measures of parts fabricated by Fused Filament Fabrication (FFF) system. An integrated framework for systematically designing experiments is proposed to achieve multiple sets of FFF process parameters resulting in optimal geometry integrity. The proposed method is validated using a real world case study. The results show that optimal properties are achieved in a more efficient manner compared with existing methods.more » « less
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Part design and process parameters directly influence the spatiotemporal distribution of temperature and associated heat transfer in parts made using additive manufacturing (AM) processes. The temporal evolution of temperature in AM parts is termed herein as thermal profile or thermal history. The thermal profile of the part, in turn, governs the formation of defects, such as porosity and shape distortion. Accordingly, the goal of this work is to understand the effect of the process parameters and the geometry on the thermal profile in AM parts. As a step towards this goal, the objectives of this work are two-fold: (1) to develop and apply a finite element-based framework that captures the transient thermal phenomena in the fused filament fabrication (FFF) additive manufacturing of acrylonitrile butadiene styrene (ABS) parts, and (2) validate the model-derived thermal profiles with experimental in-process measurements of the temperature trends obtained under different feed rate settings (viz., the translation velocity, also called scan speed or deposition speed, of the extruder on the FFF machine). In the specific context of FFF, this foray is the critical first-step towards understanding how and why the thermal profile directly affects the degree of bonding between adjacent roads (linear track of deposited material), which in turn determines the strength of the part, as well as, propensity to form defects, such as delamination. From the experimental validation perspective, we instrumented a Hyrel Hydra FFF machine with three non-contact infrared temperature sensors (thermocouples) located near the nozzle (extruder) of the machine. These sensors measure the surface temperature of a road as it is deposited. Test parts are printed under three different settings of feed rate, and subsequently, the temperature profiles acquired from the infrared thermocouples are juxtaposed against the model-derived temperature profiles. Comparison of the experimental and model-derived thermal profiles confirms a high-degree of correlation therein, with maximum absolute error less than 10%. This work thus presents one of the first efforts in validation of thermal profiles in FFF via in-process sensing. In our future work, we will focus on predicting defects, such as delamination and inter-road porosity based on the thermal profile.more » « less
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Abstract Part design and process parameters directly influence the instantaneous spatiotemporal distribution of temperature in parts made using additive manufacturing (AM) processes. The temporal evolution of temperature in AM parts is termed herein as the thermal profile or thermal history. The thermal profile of the part, in turn, governs the formation of defects, such as porosity and shape distortion. Accordingly, the goal of this work is to understand the effect of the process parameters and the geometry on the thermal profile in AM parts. As a step toward this goal, the objectives of this work are two-fold. First, to develop and apply a finite element-based framework that captures the transient thermal phenomena in the fused filament fabrication (FFF) additive manufacturing of acrylonitrile butadiene styrene (ABS) parts. Second, validate the model-derived thermal profiles with experimental in-process measurements of the temperature trends obtained under different material deposition speeds. In the specific context of FFF, this foray is the critical first-step toward understanding how and why the thermal profile directly affects the degree of bonding between adjacent roads (linear track of deposited material), which in turn determines the strength of the part, as well as, propensity to form defects, such as delamination. From the experimental validation perspective, we instrumented a Hyrel Hydra FFF machine with three non-contact infrared temperature sensors (thermocouples) located near the nozzle (extruder) of the machine. These sensors measure the surface temperature of a road as it is deposited. Test parts are printed under three different settings of feed rate, and subsequently, the temperature profiles acquired from the infrared thermocouples are juxtaposed against the model-derived temperature profiles. Comparison of the experimental and model-derived thermal profiles confirms a high degree of correlation therein, with a mean absolute percentage error less than 6% (root mean squared error <6 °C). This work thus presents one of the first efforts in validating thermal profiles in FFF via direct in situ measurement of the temperature. In our future work, we will focus on predicting defects, such as delamination and inter-road porosity based on the thermal profile.more » « less
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Conference Paper:
- https://doi.org/doi.org/10.13140/RG.2.2.32731.90407
