Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study
Additive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecting the quality and functionality of 3D-printed par...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-06-01
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| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/15/13/2893 |
| _version_ | 1797590955414519808 |
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| author | Hussein Alzyod Peter Ficzere |
| author_facet | Hussein Alzyod Peter Ficzere |
| author_sort | Hussein Alzyod |
| collection | DOAJ |
| description | Additive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecting the quality and functionality of 3D-printed parts. This study conducts a comprehensive finite element analysis (FEA) to investigate the material-dependent impact of key printing parameters on residual stress and warpage deformation in 3D printing. The research focuses on three distinct materials: polyetherimide (PEI), acrylonitrile butadiene styrene (ABS), and polyamide 6 (PA6). Various printing parameters are systematically varied, including printing temperature, printing speed, bed temperature, infill density, layer thickness, and infill pattern. The study employs the Taguchi L27 orthogonal array and employs the analysis of variance (ANOVA) statistical technique to assess the significance of the input parameters. The obtained results reveal that certain parameters exhibit a greater sensitivity to material differences, whereas the layer thickness parameter demonstrates a relatively lower sensitivity. Notably, infill density and printing temperature play a crucial role in reducing residual stress for PA6, while the infill pattern parameter proves to be a significant contributor to minimizing warpage deformation across all three materials. These findings underscore the importance of conducting material-specific analyses to optimize 3D printing parameters and achieve the desired quality outcomes while mitigating residual stress and warpage deformation. |
| first_indexed | 2024-03-11T01:31:46Z |
| format | Article |
| id | doaj.art-de16ebea52eb4e008903205761d91dca |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-11T01:31:46Z |
| publishDate | 2023-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-de16ebea52eb4e008903205761d91dca2023-11-18T17:21:41ZengMDPI AGPolymers2073-43602023-06-011513289310.3390/polym15132893Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis StudyHussein Alzyod0Peter Ficzere1Department of Railway Vehicles and Vehicle System Analysis, Faculty of Transportation Engineering and Vehicle Engineering, Budapest University of Technology and Economics, Műegyetem rkp.3, H-1111 Budapest, HungaryDepartment of Railway Vehicles and Vehicle System Analysis, Faculty of Transportation Engineering and Vehicle Engineering, Budapest University of Technology and Economics, Műegyetem rkp.3, H-1111 Budapest, HungaryAdditive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecting the quality and functionality of 3D-printed parts. This study conducts a comprehensive finite element analysis (FEA) to investigate the material-dependent impact of key printing parameters on residual stress and warpage deformation in 3D printing. The research focuses on three distinct materials: polyetherimide (PEI), acrylonitrile butadiene styrene (ABS), and polyamide 6 (PA6). Various printing parameters are systematically varied, including printing temperature, printing speed, bed temperature, infill density, layer thickness, and infill pattern. The study employs the Taguchi L27 orthogonal array and employs the analysis of variance (ANOVA) statistical technique to assess the significance of the input parameters. The obtained results reveal that certain parameters exhibit a greater sensitivity to material differences, whereas the layer thickness parameter demonstrates a relatively lower sensitivity. Notably, infill density and printing temperature play a crucial role in reducing residual stress for PA6, while the infill pattern parameter proves to be a significant contributor to minimizing warpage deformation across all three materials. These findings underscore the importance of conducting material-specific analyses to optimize 3D printing parameters and achieve the desired quality outcomes while mitigating residual stress and warpage deformation.https://www.mdpi.com/2073-4360/15/13/2893residual stresswarpage deformationfused filament fabricationoptimizationfinite element analysisTaguchi method |
| spellingShingle | Hussein Alzyod Peter Ficzere Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study Polymers residual stress warpage deformation fused filament fabrication optimization finite element analysis Taguchi method |
| title | Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study |
| title_full | Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study |
| title_fullStr | Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study |
| title_full_unstemmed | Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study |
| title_short | Material-Dependent Effect of Common Printing Parameters on Residual Stress and Warpage Deformation in 3D Printing: A Comprehensive Finite Element Analysis Study |
| title_sort | material dependent effect of common printing parameters on residual stress and warpage deformation in 3d printing a comprehensive finite element analysis study |
| topic | residual stress warpage deformation fused filament fabrication optimization finite element analysis Taguchi method |
| url | https://www.mdpi.com/2073-4360/15/13/2893 |
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