| dc.description.abstract |
Fused deposition modelling (FDM) has recently emerged as a prominent additive
manufacturing technology. This technology allows designers to manufacture physical
components with complex geometry entirely from various engineering thermoplastics
without requiring specialised tools. The FDM process parameters improves the
mechanical properties, reduce processing duration, and enhance the accuracy of the
components. As a result, this technology faces considerable difficulties regarding the
quality and functionality of the produced components. The anisotropic characteristics
of the object created in the FDM process are well acknowledged because to their
reliance on numerous conflicting process factors. It is crucial to gain a comprehensive
understanding of the process’s strengths and weaknesses to optimise the parameters
influencing the part’s quality and performance under different loading conditions.
This, consequently, ensures that the component operates as per real time requirements.
In literature analysis, 3D printing has been proposed for producing real time used
product, and it is also feasible to print for more advance uses. Polymer composites are
emerging that may be suitable for fabrication of real time applications product through
3D printing, obviating the need for the subtractive manufacturing steps associated with
the traditional workflow. Few studies have demonstrated the use of nano particles
reinforced composite as the future of 3d printing elevating the mechanical properties
for real time applications. Several studies have investigated the effect of various
potential process parameters (layer thickness, raster width etc.) on the mechanical
properties of the FDM products. FDM type of additive manufacturing has been
demonstrated as the affordable and easily available option. FDM has been
demonstrated as the least expensive additive manufacturing.
This study presents a systematic study on the development of high-performance
Polylactic Acid-Nano Graphene (PLA-nGr) composites for real time applications
using FDM technology. Following that, the reinforcements were added at varying
weight proportions of 1.5%, 3%, 4.5%, and 6% nano Graphene by weight to PLA
respectively. Melt Flow Index and Differential Scanning Calorimetric test has been
used for finalizing the composition of reinforcement. 4.5 wt% Nano Graphene
reinforced PLA is found to be more thermally stable than other PLA compositions
(1.5%, 3%, and 6% nano Graphene by weight to PLA) based on the findings of
crystallinity and endothermic enthalpy. After finalizing the composition, filament has
been fabricated using EVO felfill extruder.
Further study focuses on methodically varying FDM process parameters including
nozzle temperature, infill pattern and infill density. Three samples of each composition
(PLA + 4.5% Nano Graphene) for different levels of three different processing
parameters, Extrusion temperature (190 °C, 200 °C, 210 °C, 220 °C, 220 °C, 230 °C,
iv
240 °C), Infill pattern (Gyroid, Honeycomb, Rectilinear) and Infill density (40%,
50%, 60%) have been printed for Tensile test, Impact Strength, Wear rate,
Compressive strength and Surface Roughness as per ASTM standard. L18 OA has
been used as per design of experiment. Through rigorous experimental trials,
supported by statistical optimization tools Design of Experiments (DOE), Taguchi
methods, and ANOVA, the research has successfully identified optimal conditions
under which FDM-processed PLA/nano graphene nanocomposites exhibit superior
structural integrity and functional performance. This work elucidates the experimental
findings of an inquiry into the influence of key FDM process parameters on various
quality metrics, including physical (dimensional accuracy, surface roughness) and
mechanical (tensile strength, impact resistance, compressive strength, wear rate)
properties. This study thoroughly investigates the independent and interactive effects
of FDM process parameters on these properties through diverse experimental
procedures and analysis of variance (ANOVA).
The findings of this research will help advance the use of 3D printing in the
Automotive sector where strength - Impact, Tensile, wear resistance, biocompatibility,
and surface quality are crucial factors. This study offers a significant advancement in
the field of additive manufacturing, particularly in optimizing FDM processes for
enhanced material performance through the integration of nanomaterials with FDM
technology, paving the way for advanced applications in aerospace, automotive,
biomedical, and electronics domains.
This research primarily contributes by establishing new correlations between FDM
process parameters and the quality attributes of newly developed PLA-nGr material.
This work has shown novel avenues for comprehensive research by offering systematic
methodologies for leveraging the benefits of FDM. The findings indicate that the FDM
process parameters significantly affect the quality and performance of the
manufactured components. Optimised process parameters give a promising possibility
for development. This study’s conclusions provide technical and scientific insights that
could promptly enhance the additive manufacturing industry by augmenting product
quality, efficiency, and mechanical properties.
The results are analysed, discussed, and evaluated following the validation of
optimal process parameters and their comparison to the strengths of actual
components. The study’s proposed approach and analytical tools are broadly
applicable and will be utilised across various AM technologies, especially for
nonlinear systems with multiple inputs and the management of numerous
interdependent outputs. The study’s pragmatic recommendations for choosing FDM
fabrication parameters will enhance the quality and functionality of generated
components across several sectors, while also promoting further improvements in
FDM systems. |
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