Investigation of the mechanical properties, surface quality, and energy efficiency of a fused filament fabrication for PA6

Author:

Mushtaq Ray Tahir1,Wang Yanen1,Rehman Mudassar1,Khan Aqib Mashood2,Bao Chengwei13,Sharma Shubham45,Eldin Sayed M.6,Abbas Mohamed7

Affiliation:

1. Bio-Additive Manufacturing University-Enterprise Joint Research Center of Shaanxi Province, Department of Industry Engineering, Northwestern Polytechnical University , Xi’an 710072 , China

2. Faculty of Engineering and Technology, Department of Mechatronics Engineering, University of Chakwal , Chakwal , 48800 , Pakistan

3. School of Intelligent Manufacturing and Control Technology, Xi’an Mingde Institute of Technology , Xi’an 710124 , China

4. Mechanical Engineering Department, University Center for Research and Development, Chandigarh University , Mohali , Punjab, 140413 , India

5. School of Mechanical and Automotive Engineering, Qingdao University of Technology , 266520 , Qingdao , China

6. Faculty of Engineering, Center for Research, Future University in Egypt , New Cairo , 11835 , Egypt

7. Electrical Engineering Department, College of Engineering, King Khalid University , Abha 61421 , Saudi Arabia

Abstract

Abstract Practitioners in the industry are developing predictive methods for assessing key parameters and responses of engineering materials. The aim of this research is to optimize the average surface roughness (R a), flexural strength (FS), tensile strength (TS), print time (T), and print energy consumption (E) of 3D printed Nylon 6 (PA6). Quantitative parameters for infill density (ID), layer thickness (LT), and print speed (PS) were selected. Employing the central component design (CCD)-response surface methodology (RSM) for investigational design, statistical analysis, and multi-objective optimization, a total of 20 samples were produced and analyzed to develop prediction models. The implication of the selected parameters was confirmed through variance analysis (ANOVA), and the models were validated using confirmatory trial tests. It was found that LT was essential in achieving appropriate R a and T values, while ID was a crucial factor in obtaining the necessary mechanical properties. RSM optimization led to an FS of 70.8 MPa, TS of 40.8 MPa, lowest T of 53 min, lowest possible R a of 8.30 µm, and 0.203 kW·h “E” at ID = 84%, LT = 0.21 mm, and PS = 75 mm·s−1. The study also revealed weak bond strength between layers and layers debonding after bending tests, as shown in SEM micrographs. The PA6 material exhibited flexibility during tensile testing, going into plasticity before breaking. The created numerically optimized model is anticipated to benefit manufacturers and practitioners in predicting the required surface quality for various factors before conducting experiments, ultimately improving 3D printing (3DP) processes and outcomes. Despite limitations such as limited parameter selection, small sample size, and material-specific focus, this research presents valuable insights for the 3DP industry.

Publisher

Walter de Gruyter GmbH

Subject

Condensed Matter Physics,General Materials Science

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