FEASIBILITY STUDY OF ULTRASONIC FREQUENCY APPLICATION ON FDM TO IMPROVE PARTS SURFACE FINISH
DOI:
https://doi.org/10.11113/jt.v77.6983Keywords:
Additive manufacturing, fuse deposition modeling, ultrasonic frequencyAbstract
Fuse Deposition Modeling (FDM) offer several advantages such as less expensive material, lack of expensive lasers and allows complex geometry to be built. However, FDM have limitations such as seam lines appear between layers and excess material residue, leading to surface roughness and poor finish. Ultrasound has been applied in various conventional machining process and shows good machined surface finish. However, from the literature review, it was found there is no investigation made on the application of ultrasound for Additive Manufacturing (AM) especially for FDM. This paper presents an adaptive approach to improve surface finish of FDM sample by applying ultrasonic vibration. The papers discuss the result of the surface finish of test piece printed via a desktop FDM system whereby an ultrasound device that was securely mounted onto the platform during printing process. Frequency that was used in the experiment is 11, 16 and 21 kHz with acrylonitrile butadiene styrene (ABS) material. Optical microscope with the aid of pro VIS software version 2.90 was used to measure the surface roughness of the four samples printed with a vibration in the above specified frequency. It was found that a 21 kHz frequency applied to the FDM process achieved the best surface finish due to less surface defects found and thickness had finer layers being produced. The results from this study could potentially be applied to other AM system such as the selective laser sintering, electron beam machining and stereolithography. The new data on effects of ultrasonic FDM technique and machining parameter for achieving improved surface finish has potential benefit to be used in various industries such as automotive, consumer, medical, sports, etc to produce prototypes or customized end used product or part. The data will benefit in term of product design and development elimination of manual post processing. Further study that could be done is to use different types of material such as polyactic acid (PLA) or composite material.
References
Wohlers, T. 2013. Additive manufacturing and 3D printing State of the industry. Wohlers Associates, Fort Collins, CO.
McCullough, E. J., & Yadavalli, V. K. 2013. Surface modification of fused deposition modeling ABS to enable rapid prototyping of biomedical microdevices. Journal of Materials Processing Technology. 213(6): 947-954.
P. Jain, A. M. Kuthe., 2013. Feasibility Study of Manufacturing Using Rapid Prototyping: FDM Approach. Procedia Engineering. 63: 4-11.
Sood, A. K., Ohdar, R. K., Mahapatra, S.S. 2012. Experimental Investigation and Empirical Modeling of FDM Process for Compressive Strength Improvement. Journal of Advanced Research. 3(1): 81-90.
Yang, J.J., Zhang, H., Deng, X.Z., Wei, B.Y. 2013. Ultrasonic Lapping of Hypoid Gear: System Design and Experiments. Mechanism and Machine Theory. 65: 71-78.
Kim, W. J., Lu, F., Cho, S. H., Park, J.K., Lee, M.G. 2011. Design and Optimization of Ultrasonic Vibration Mechanism using PZT for Precision Laser Machining. Physics Procedia. 19: 258-264.
M. Nad, 2010. Ultrasonic Horn Design for Ultrasonic Machining Technologies. Applied and Computational Mechanics. 4(1).
Wang, J., Shimada, K., Mizutani, M., Kuriyagawa, T. 2013. Material Removal During Ultrasonic Machining Using Smoothed Particle Hydrodynamics. Journal ref: International Journal of Automation Technology. 7(6): 614-620.
Kang, B., Kim, G. W., Yang, M., Cho, S. H., & Park, J. K. 2012. A study on the effect of ultrasonic vibration in nanosecond laser machining. Optics and Lasers in Engineering. 50(12): 1817-1822.
Tabatabaei, S. M. K., Behbahani, S., & Mirian, S. M. 2013. Analysis of ultrasonic assisted machining (UAM) on regenerative chatter in turning. Journal of Materials Processing Technology. 213(3): 418-425.
Friel, R. J., & Harris, R. A. 2013. Ultrasonic Additive Manufacturing–A Hybrid Production Process for Novel Functional Products. Procedia CIRP. 6: 35-40.
Nik, M. G., Movahhedy, M. R., & Akbari, J. 2012. Ultrasonic-assisted grinding of Ti6Al4V alloy. Procedia CIRP. 1: 353-358.
Kim, W. J., Lu, F., Cho, S. H., Park, J. K., & Lee, M. G. 2011. Design and optimization of ultrasonic vibration mechanism using PZT for precision laser machining. Physics Procedia.19: 258-264.
Lian, H., Guo, Z., Huang, Z., Tang, Y., & Song, J. 2013. Experimental research of Al6061 on ultrasonic vibration assisted micro-milling. Procedia CIRP. 6: 561-564.
Galantucci, L. M., Lavecchia, F., Percoco, G. 2010. Quantitative Analysis of a Chemical Treatment to Reduce Roughness of Parts Fabricated Using Fused Deposition Modeling. CIRP Annals-Manufacturing Technology. 59(1): 247-250.
Phatak, A. M., & Pande, S. S. 2012. Optimum part orientation in Rapid Prototyping using genetic algorithm. Journal Of Manufacturing Systems. 31(4): 395-402.
Kantaros, A., & Karalekas, D. 2013. Fiber Bragg grating based investigation of residual strains in ABS parts fabricated by fused deposition modeling process. Materials & Design. 50: 44-50.
Maidin, S., Abdul Aziz, K. F., Muhamad, M. K., Pei, E. 2014. Analysis of Applying Ultrasonic Frequency on a Desktop FDM Nozzle. International Conference on Design and Concurrent Engineering 3rd iDECON, 22-23 September 2014.
Downloads
Published
Issue
Section
License
Copyright of articles that appear in Jurnal Teknologi belongs exclusively to Penerbit Universiti Teknologi Malaysia (Penerbit UTM Press). This copyright covers the rights to reproduce the article, including reprints, electronic reproductions, or any other reproductions of similar nature.
