Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

Fused deposition modeling (FDM) is one of the most affordable and widespread additive manufacturing (AM) technologies. Despite its simplistic implementation, the physics behind this FDM process is very complex and involves rapid heating and cooling of the polymer feedstock. As a result, highly non-u...

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Autores principales:	Daniyar Syrlybayev, Beibit Zharylkassyn, Aidana Seisekulova, Asma Perveen, Didier Talamona
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	warpage finite element analysis (fem) FDM Taguchi multilateral Organic chemistry QD241-441
Acceso en línea:	https://doaj.org/article/aabb80ffeea04a7681b19a592b57c9c9
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id	oai:doaj.org-article:aabb80ffeea04a7681b19a592b57c9c9
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spelling	oai:doaj.org-article:aabb80ffeea04a7681b19a592b57c9c92021-11-11T18:49:04ZOptimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method10.3390/polym132138492073-4360https://doaj.org/article/aabb80ffeea04a7681b19a592b57c9c92021-11-01T00:00:00Zhttps://www.mdpi.com/2073-4360/13/21/3849https://doaj.org/toc/2073-4360Fused deposition modeling (FDM) is one of the most affordable and widespread additive manufacturing (AM) technologies. Despite its simplistic implementation, the physics behind this FDM process is very complex and involves rapid heating and cooling of the polymer feedstock. As a result, highly non-uniform internal stresses develop within the part, which can cause warpage deformation. The severity of the warpage is highly dependent on the process parameters involved, and therefore, currently extensive experimental studies are ongoing to assess their influence on the final accuracy of the part. In this study, a thermomechanical Finite Element model of the 3D printing process was developed using ANSYS. This model was compared against experimental results and several other analytical models available in the literature. The developed Finite Element Analysis (FEA) model demonstrated a good qualitative and quantitative correlation with the experimental results. An L9 orthogonal array, from Taguchi Design of Experiments, was used for the optimization of the warpage based on experimental results and numerical simulations. The optimum process parameters were identified for each objective and parts were printed using these process parameters. Both parts showed an approximately equal warpage value of 320 μm, which was the lowest among all 10 runs of the L9 array. Additionally, this model is extended to predict the warpage of FDM printed multi-material parts. The relative percentage error between the numerical and experimental warpage results for alternating and sandwich specimens are found to be 1.4% and 9.5%, respectively.Daniyar SyrlybayevBeibit ZharylkassynAidana SeisekulovaAsma PerveenDidier TalamonaMDPI AGarticlewarpagefinite element analysis (fem)FDMTaguchimultilateralOrganic chemistryQD241-441ENPolymers, Vol 13, Iss 3849, p 3849 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	warpage finite element analysis (fem) FDM Taguchi multilateral Organic chemistry QD241-441
spellingShingle	warpage finite element analysis (fem) FDM Taguchi multilateral Organic chemistry QD241-441 Daniyar Syrlybayev Beibit Zharylkassyn Aidana Seisekulova Asma Perveen Didier Talamona Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method
description	Fused deposition modeling (FDM) is one of the most affordable and widespread additive manufacturing (AM) technologies. Despite its simplistic implementation, the physics behind this FDM process is very complex and involves rapid heating and cooling of the polymer feedstock. As a result, highly non-uniform internal stresses develop within the part, which can cause warpage deformation. The severity of the warpage is highly dependent on the process parameters involved, and therefore, currently extensive experimental studies are ongoing to assess their influence on the final accuracy of the part. In this study, a thermomechanical Finite Element model of the 3D printing process was developed using ANSYS. This model was compared against experimental results and several other analytical models available in the literature. The developed Finite Element Analysis (FEA) model demonstrated a good qualitative and quantitative correlation with the experimental results. An L9 orthogonal array, from Taguchi Design of Experiments, was used for the optimization of the warpage based on experimental results and numerical simulations. The optimum process parameters were identified for each objective and parts were printed using these process parameters. Both parts showed an approximately equal warpage value of 320 μm, which was the lowest among all 10 runs of the L9 array. Additionally, this model is extended to predict the warpage of FDM printed multi-material parts. The relative percentage error between the numerical and experimental warpage results for alternating and sandwich specimens are found to be 1.4% and 9.5%, respectively.
format	article
author	Daniyar Syrlybayev Beibit Zharylkassyn Aidana Seisekulova Asma Perveen Didier Talamona
author_facet	Daniyar Syrlybayev Beibit Zharylkassyn Aidana Seisekulova Asma Perveen Didier Talamona
author_sort	Daniyar Syrlybayev
title	Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method
title_short	Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method
title_full	Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method
title_fullStr	Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method
title_full_unstemmed	Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method
title_sort	optimization of the warpage of fused deposition modeling parts using finite element method
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/aabb80ffeea04a7681b19a592b57c9c9
work_keys_str_mv	AT daniyarsyrlybayev optimizationofthewarpageoffuseddepositionmodelingpartsusingfiniteelementmethod AT beibitzharylkassyn optimizationofthewarpageoffuseddepositionmodelingpartsusingfiniteelementmethod AT aidanaseisekulova optimizationofthewarpageoffuseddepositionmodelingpartsusingfiniteelementmethod AT asmaperveen optimizationofthewarpageoffuseddepositionmodelingpartsusingfiniteelementmethod AT didiertalamona optimizationofthewarpageoffuseddepositionmodelingpartsusingfiniteelementmethod
_version_	1718431718364413952

Optimization of the Warpage of Fused Deposition Modeling Parts Using Finite Element Method

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