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  • PARAMETRIC OPTIMIZATION OF FUSED DEPOSITION

    MODELING USING RESPONSE SURFACE METHODOLOGY

    A THESIS SUBMITTED IN PARTIAL FULFILLMENT

    FOR THE REQUIREMENT FOR THE DEGREE OF

    Master of Technology

    in

    Production Engineering

    by

    VEDANSH CHATURVEDI

    Department of Mechanical Engineering

    National Institute of Technology

    Rourkela – 8

    2009

  • PARAMETRIC OPTIMIZATION OF FUSED DEPOSITION

    MODELING USING RESPONSE SURFACE METHODOLOGY

    A THESIS SUBMITTED IN PARTIAL FULFILLMENT

    FOR THE REQUIREMENT FOR THE DEGREE OF

    Master of Technology

    in

    Production Engineering

    by

    VEDANSH CHATURVEDI

    Under the guidance of

    Dr. S. S. MAHAPATRA

    Professor, Department of Mechanical Engineering

    Department of Mechanical Engineering

    National Institute of Technology

    Rourkela – 8

    2009

  • National Institute of Technology

    Rourkela

    CERTIFICATE

    This is to certify that the thesis entitled, “PARAMETRIC OPTIMIZATION OF

    FUSED MODELING USING RESPONSE SURFACE METHODOLOGY”

    submitted by Vedansh Chaturvedi in partial fulfillment of the requirements for the

    award of Master of Technology Degree in Mechanical Engineering with

    specialization in Production Engineering at the National Institute of Technology,

    Rourkela (deemed University) is an authentic work carried out by him under my

    supervision and guidance.

    To the best of my knowledge, the matter embodied in the thesis has not submitted

    to any other University/Institute for the award of any degree or diploma.

    Dr. S. S. Mahapatra

    Date: Dept. of Mechanical Engineering

    National Institute of Technology

    Rourkela – 769008

  • ACKNOWLEDGEMENT

    I would like to express my deep sense of respect and gratitude toward my supervisor Dr. S. S.

    Mahapatra, who not only guided the academic project work but also stood as a teacher and

    philosopher in realizing the imagination in pragmatic way, I want to thank him for introducing

    me for the field of Optimization and giving the opportunity to work under him. His presence and

    optimism have provided an invaluable influence on my career and outlook for the future. I

    consider it my good fortune to have got an opportunity to work with such a wonderful person.

    I express my gratitude to Dr. R. K. Sahoo, Professor and Head, Department of Mechanical

    Engineering, faculty member and staff of Department of Mechanical Engineering for extending

    all possible help in carrying out the dissertation work directly or indirectly. They have been great

    source of inspiration to me and I thank them from bottom of my heart. I like to express my

    gratitude to Dr. Saurav Datta, Lecturer, Department of Mechanical Engineering , for his

    valuable advice in carrying out Literature review.

    I am especially indebted to my parents for their love, sacrifices and support. They are my

    teachers after I came to this world and have set great example for me about how to live, study

    and work.

    VEDANSH CHATURVEDI

  • i

    CONTENTS

    TITLE PAGE NO.

    Abstract iv

    List of Figures v

    List of Tables vii

    Nomenclature viii

    1. An introduction of rapid prototyping process 1

    1.1 Overview of rapid prototyping process 1

    1.2 The basic process 2

    1.3 Rapid prototyping technique 4

    1.3.1 Stereolithography 4

    1.3.2 Selective layer sintering 6

    1.3.3 Laminated object manufacturing 8

    1.3.4 Fused deposition modeling 11

    1.4 Objective of Research Work 12

    2. Literature review 15

    3. Fused deposition modeling and ABS material 20

    3.1 Fused deposition modeling 20

    3.2 ABS material 23

    3.3 Properties of ABS plastic 24

    4. Response surface methodology 27

    4.1 Response surface methodology and robust design 30

  • ii

    4.2 The sequential nature of the response surface methodology 31

    4.3 Building empirical models 32

    4.3.1 Linear regression model 32

    4.3.2 Estimation of the parameter in linear regression model 33

    4.3.3 Model adequacy checking 34

    4.3.4 Properties of the least square estimation regression model 34

    4.3.5 Residual analysis 36

    4.4 Variable selection and model building in regression 37

    4.4.1 Procedure for variable selection 38

    4.4.2 All possible regression 38

    4.4.3 Stepwise regression analysis 39

    5. Specimen preparation, Experiment and analysis 41

    5.1 Specimen preparation 41

    5.2 Testing of specimen