UNIVERSITI TEKNIKAL MALAYSIA MELAKA OPTIMIZATION …eprints.utem.edu.my/16592/1/Optimization Of FDM...
Transcript of UNIVERSITI TEKNIKAL MALAYSIA MELAKA OPTIMIZATION …eprints.utem.edu.my/16592/1/Optimization Of FDM...
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
OPTIMIZATION OF FDM PARAMETERS WITH TAGUCHI
METHOD FOR PRODUCTION OF FLEXIBLE ABS PART
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) with Honours.
by
HO KAM YUEN
B051210023
910216065499
FACULTY OF MANUFACTURING ENGINEERING
2015
UNIVERSITI TEKNIKAL MALAYSIA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Optimization of FDM Parameters with Taguchi Method for Production of Flexible ABS Part
SESI PENGAJIAN: 2014/15 Semester 2 Saya HO KAM YUEN mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( )
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap: Blok B-00-28, Taman Putra Budiman,
43300 Seri Kembangan,
Selangor. Tarikh: ________________________
Disahkan oleh:
Cop Rasmi: Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM
as a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Manufacturing Design) (Hons.). The member of the
supervisory is as follow:
………………………………
(DR. SHAJAHAN BIN MAIDIN)
DECLARATION
I hereby, declared this report entitled “Optimization of FDM Parameters with
Taguchi Method for Production of Flexible ABS Part” is the results of my own
research except as cited in the references.
Signature : …………………………
Author’s Name : Ho Kam Yuen
Date : 29th June 2015
i
ABSTRAK
Kaedah Taguchi adalah alat yang berkesan diperkenalkan bagi mengoptimumkan kualiti
produk atau proses. Produk yang dihasilkan dengan bahan ABS oleh teknologi Fused
Deposition Modelling (FDM) mengatakan prestasi produk berbeza dengan perubahan
parameter proses mesin seperti ketebalan lapisan, sudut raster, jurang udara raster, dan
beberapa yang lain. Prestasi produk yang dihasilkan menguna mesin FDM desktop diukur
dalam aspek membuang jarak objek dengan produk. Dalam usaha untuk mencapai prestasi
optimum bagi produk yang dihasilkan, kaedah Taguchi telah dilaksanakan kerana ia
adalah satu kaedah yang mudah tetapi berkuasa untuk reka bentuk uji kaji menggunakan
kaedah orthogonal array. Dalam projek ini, orthogonal array L9 (33) telah digunakan dan
9 keping sampel telah ditentukan untuk 3 parameter iaitu: ketebalan lapisan, corak infill
dan kepadatan infill dengan 3 tahap bagi setiap parameter. Sampel telah direka
menggunakan SolidWorks dan mesin FDM desktop FlashForge Dreamer telah digunakan
untuk membina 9 sampel tersebut. Sampel kemudiannya diuji ke atas prestasinya dalam
membaling objek dengan sudut anjakan berbeza 10º, 15º dan 20º. Keputusan telah
diperolehi dan data dianalisis. Data menunjukkan bahawa sampel dengan gabungan
parameter ketebalan 0.2mm lapisan, corak isian heksagon dan 60% ketumpatan infill
masing-masing mencapai purata jarak membaling terpanjang 52cm, 92cm dan 126.67cm
bagi sudut anjakan 10º, 15º dan 20º. Oleh itu, keputusan ini menunjukkan bahawa ciri-ciri
produk yang dihasilkan dengan menggunakan mesin FDM berbeza dengan kombinasi
yang berbeza parameter proses dan Kaedah Taguchi menyediakan penyelesaian
menentukan kombinasi yang optimum dengan jumlah minimum eksperimen.
ii
ABSTRACT
Taguchi Method is an effective tool introduced for the optimization of the product or
process quality. The ABS product produced by Fused Deposition Modeling (FDM) has it
performance varies with the changes of the process parameters of the machine such as
layer thickness, raster angle, air gaps and some others. The performance of the part
produced via a desktop FDM machine was measured with the aspect of throwing distance
of an object by the part. In order to achieve the optimum performance of the produced
part, the Taguchi method was employed because it is a simplified yet powerful method
for experimental design using the orthogonal array method. In this project, an orthogonal
array of L9 (33) was used and 9 pieces of samples were determined for 3 parameters
namely: layer thickness, infill pattern and infill density with 3 levels each. The sample
was designed using SolidWorks and FlashForge Dreamer a desktop FDM machine was
used to fabricate the 9 samples. The samples were then tested on its performance in
throwing objects with different displacement angles of 10º, 15º and 20º. The results were
obtained and data was analyzed. The data shows that the samples with parameters
combination of 0.2mm layer thickness, hexagon infill pattern and 60% infill density
achieved the longest average throwing distance of 52cm, 92cm and 126.67cm for
displacement angles of 10º, 15º and 20º respectively. Thus, this result shows that the
properties of a product produced using FDM machine varies with different combination
of process parameters and the Taguchi Method provides the solution of determining the
optimum combination with minimum number of experiment.
iii
DEDICATION
I would like to dedicate this work to my
Beloved parents
Dearest siblings
Honorable supervisor and lecturers
Supportive friends and mates
iv
ACKNOWLEDGEMENT
I would like to use this opportunity to express my gratitude to everyone who supported
me throughout the completion of the report for Final Year Project. I am thankful for their
guidance, criticism and also advice during the project.
I would like to express my thanks to my project supervisor, Dr. Shajahan bin Maidin for
his support and guidance during the whole project. I would also like to thank to my family,
course mate and my friends who provide me all the supports all along the progress and
completion of the Final Year Project report.
v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List of Equations xi
CHAPTER 1: INTRODUCTION 1
1.1 Introduction 1
1.2 Problem Statement 2
1.3 Aims 2
1.4 Objectives 3
1.5 Scope 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 Additive Manufacturing (AM) 4
2.1.1 Advantages and Limitations of AM 6
2.1.2 Applications of AM 7
vi
2.1.2.1 Medical Applications 9
2.1.2.2 Automotive Applications 10
2.1.2.3 Architectural Applications 11
2.2 Fused Deposition Modeling (FDM) 12
2.2.1 Working Principle of FDM 12
2.2.2 Parameters of FDM 16
2.2.3 Material of FDM 18
2.3 Experimental Methods and Tools 23
2.3.1 The Taguchi Method 23
2.3.1.1 Taguchi Design of Experiment Process 24
2.3.1.2 Orthogonal Array (OA) 26
2.3.1.3 Signal-to-Noise Ratio (S/N Ratio) 28
2.3.1.4 Analysis of Variance (ANOVA) 28
2.3.2 Applications of Taguchi Methods 30
CHAPTER 3: METHODOLOGY 32
3.1 Project Planning 32
3.1.1 Background Study 33
3.1.2 Preparation of the Sample 34
3.1.3 Preparing and Running of Experiment 36
3.1.4 Preparation of Report 37
3.2 Gantt Chart 38
vii
CHAPTER 4: RESULTS AND DISCUSSIONS 40
4.1 Preparation of Samples 40
4.1.1 CAD Model Generation 41
4.1.2 Tabulation of FDM Parameters 41
4.1.3 Fabrication of Samples 43
4.2 Preparation and Running of Experiment 45
4.2.1 Preparation of Experiment 46
4.2.2 Running Experiment 47
4.2.3 Result Obtaining and Data Tabulation 48
4.3 Discussions 51
CHAPTER 5: CONCLUSION AND RECOMMENDATIONS 52
5.1 Conclusion 52
5.2 Recommendations 54
REFERENCE LIST 55
viii
LIST OF TABLES
2.1 AM technologies, Acronym and development years 5
2.2 AM application timeline 7
2.3 Compilation of FDM material description 19
2.4 Compilation of some material and its properties for FDM 22
3.1 Gantt chart for Final Year Project 1 38
3.2 Gantt chart for Final Year Project 2 39
4.1 FDM parameters and its levels 42
4.2 The orthogonal array L9 (33) derived using Taguchi Method 43
4.3 Fabrication time and material required for each sample 46
4.4 Object travel distance for 10º of displacement angle 49
4.5 Object travel distance for 15º of displacement angle 49
4.6 Object travel distance for 20º of displacement angle 50
4.7 The object travel distance for 10º, 15º and 20º of displacement angle 50
ix
LIST OF FIGURES
2.1 Categories of RP technologies 5
2.2 AM application timeline 8
2.3 Example of a scaffold model 9
2.4 CAD model of scorpio rotor, a critical component for automobile 10
2.5 The example of full scale builds of construction model 11
2.6 8 generic steps of AM process 12
2.7 Process principle of FDM 15
2.8 Layout of machine component 15
2.9 FDM produced part with component material and supporting material 16
2.10 Build orientation 17
2.11 Building parameters of FDM machine 17
2.12 Raster full with Raster Direction at 90° to one and another 18
2.13 Taguchi design procedure 25
2.14 The table of array selector 26
2.15 Notation of an orthogonal array 26
2.16 Example of a L50 ( 512 ) 27
3.1 Overall project flow 33
3.2 The process for sample preparation 34
3.3 The design of a Bow model 35
x
3.4 A design of Catapult model 35
3.5 The process of running the experiment and data collection 37
4.1 Sample design using SolidWorks 41
4.2 Infill pattern from left to right representing Line, Rectangle and Hexagon 42
4.3 The infill density from left to right representing 20%, 40% and 60% 43
4.4 The FDM machine that used to fabricate the sample, FlashForge Dreamer 44
4.5 The samples fabricated using the FlashForge Dreamer 44
4.6 Setup of jigs and fixture for the experiment 46
4.7 Side view of the equipment setup (Left) and the displacement angle of 10º limits
using metal plate (Right) 47
4.8 The process of measuring the object travel distance 48
xi
LIST OF EQUATIONS
2.1 Smaller-is-better equation 28
2.2 Nominal-is-better equation 28
2.3 Larger-is-better equation 28
1
CHAPTER 1
INTRODUCTION
This chapter introduces the project and briefly describe the aims, objectives and also the
scopes. This chapter will also give an overview on the implementation of the project.
1.1 Introduction
Ever since the first commercial rapid prototype (RP) machine in 1986 which known as
Stereolithography, RP machines have been commercialized widely with many more
advance system developed in all around the world. Rapid prototyping which also known
as additive manufacturing (AM) is clearly a key technology in shortens the time of product
development for faster built of physical prototypes, tooling and models. Generally AM is
more flexible and fast in adapting the rapid changes of the product design compared to
conventional method such as casting, moulding and machining.
Fused deposition modeling (FDM) is one of the AM system uses plastic materials such as
Acrylonitrile butadiene styrene (ABS) to produce prototypes or even functional products.
The molten plastic material is ejected by nozzle layered to form the desired part which
basically in solid form or shell form. The parameters which normally take count in
2
producing good parts are the layer thickness, air gaps and raster angle. The parameters are
studied and optimized or well paired in order to ensure good quality of the output. In recent
years, Taguchi’s techniques have been widely used in the optimization for both process
design and product design, based on comprehensive experimental investigation. It is a
suitable method is determining and optimizing the parameters of the FDM machine by
pairing and testing the parameters (variables) which gives optimum output.
1.2 Problem Statement
It is important to determine the right parameters of the FDM machine in order to produce
a part which can fulfil the desire specifications. There are basically few parameters which
are important and will influence the specifications of the produced part, and these
parameters are the layer thickness, air gaps and also the raster angle. The combinations of
different setting of the parameters will definitely produce parts with different
specifications, thus the study of the suitable combination of parameters is necessary for
optimum output produced.
1.3 Aims
The aim of this project is to optimize the FDM machine parameters for flexible ABS part
using the Taguchi method approach.
3
1.4 Objectives
The objectives of the project are:
i. To study and understand the parameter of FDM influencing the performance of
the flexible ABS part,
ii. To use Taguchi method approach for design of experiment improving the FDM
parameters,
iii. To determine optimum FDM process parameters combination which results in
longest throwing distance with the ABS part.
1.5 Scope
The study covers the AM system which is the Fused deposition modeling (FDM). The
parameters of the FDM machine, FlashForge Dreamer which will serve as the focus of the
study are the layer thickness, infill pattern and infill density. The parameters optimized in
order to achieve good performance in terms of throwing distance. The material used in
producing the part is ABS type material.
4
CHAPTER 2
LITERATURE REVIEW
This chapter discuss about the related knowledge of the project which cover the
introduction of the additive manufacturing, fused deposition modeling and Taguchi
method.
2.1 Additive Manufacturing (AM)
Additive manufacturing, often been referred as 3D printing is a technology or process that
convert digital model into parts and components. This technology firstly introduced as
rapid prototype (RP) machine since the 1980s which is the Stereolithography (Lee,
Abdullah & Khan, 2005).
Rapid prototyping is referred as group of techniques that creates functional model or
components of a part or assembly layer by layer with input of 3D CAD data (Yagnik, D.,
2014) which later known as additive manufacturing. AM techniques are classified and
grouped based on each of the fundamental metal decomposition and its working principle
which shown in Figure 2.1.
5
Figure 2.1: Categories of RP technologies (Yagnik,D., 2014)
Ever since the Stereolithography is introduced, the idea has been studied and many new
processes are invented, patented and commercialized, which some has been fall out and
disappeared (Levy, Schindel, & Kruth, 2003). Table 2.1 shows the overview of the
development of the rapid prototype process and defined as additive manufacturing later.
Table 2.1: AM technologies, Acronym and development years (Levy, Schindel, &
Kruth, 2003)
AM creates object and part layer by layer, after a layer of particles are bound by heat or
chemical agent, another layer is added and repeated the binding process. Since the part or
object is created layer by layer, this technology bring benefits to the design process by
providing more freedom in part complexity which couldn’t be produced by conventional
method such as milling and casting (Adam, G.A., & Zimmer, D., 2014).
6
2.1.1 Advantages and Limitations of AM
AM gives definite competitive advantages in the aspect of geometrical freedom and
material flexibility (Levy, Schindel, & Kruth, 2003). AM techniques provides advantages
(Jauhar, S. K., & Asthankar, K. M., 2012) in:
i. Automated fabrication process
ii. Fabrication of intricate and small parts
iii. Reduced in fabrication lead time
iv. No tooling involvement
v. Elimination of process planning
vi. Product customization
vii. No scrap/waste
AM provides advantages in material saving because it considered as a “clean” build
process as it requires only the exact amount of material for the design itself. Other than
that, AM has shorter production lead time compared to the conventional processes. The
building time for a conventional machine is mostly depending to the complexity of the
part design itself, the build time is directly proportional to the amount of features consist
on that design, the more feature it have, the longer the built steps and result in longer built
time. While AM gives a distinct advantages at this aspect as the build process of a part
with AM machine will be one, which is layering the material regardless the features of the
part. Apart of that, AM requires no tooling for the part production process and this lead to
a cost reduction in the aspect of tooling and also manpower due to the automated process
of AM.
Despite of the advantages brought by AM, there are also some limitations behind it. AM
can now access a wide range of materials according to each of the processes, yet the part
produced using AM need to be refined in order to achieve the similar strength or chemical
7
characteristics of the part made by traditional manufacturing process using same material.
Besides, with the introduction of AM, the product design process has been shifted in a
different approach to design for layer manufacturing. The CAD software/systems will be
a limitations to design the model in order to have full advantages provided by AM
technologies since the current CAD software is developed based on the traditional
manufacturing processes. Accuracy of the part always a concern in AM technology. The
part produced using AM will have layered and rather rough surface finishing which
requires the assistance of post-production of finishing processes. Productivity would be
an issue for AM when comparing with the conventional processes. AM processes might
have rather low productivity compared to traditional processes but in consideration of
other factors such as the overall lead time, product complexity and more, AM would have
provide a better alternative, yet the production rate of the AM techniques still a limitation
that need to be addressed (Levy, Schindel, & Kruth, 2003).
2.1.2 Applications of AM
AM grew rapidly and its applications has expanded from prototyping to possible end-use
parts/products. There are some history of AM applications and its estimated future
developments.
Table 2.2: AM application timeline
(Royal Academy of Engineering (Great Britian), 2013)
9
AM developed from producing prototypes to building end-use product and bring
significant changes to sectors like medical, aerospace/automotive and recently the
architecture sector.
2.1.2.1 Medical Applications
With the unique characteristics of AM which is the great geometrical freedom promotes
the expansion of its application to medical field due to the body structure varies among
patients. (Su et al, 2012) The application of AM in medical field helps in fabricating parts
for implant surgery such as scaffold.
Figure 2.3: Example of a scaffold model (Su et al, 2012)
Fabrication of scaffold using conventional processes hard due to the porous structure, thus
AM is brought into attention as the scaffold could be fabricated with the regenerating of
the CAD model which could be done using the CT scanner and leave everything to the