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Research Papers

A Study of Build Edge Profile for Prediction of Surface Roughness in Fused Deposition Modeling

[+] Author and Article Information
Mohammad Taufik

Mechanical Engineering Discipline,
PDPM Indian Institute
of Information Technology,
Design and Manufacturing Jabalpur,
Jabalpur 482005, Madhya Pradesh, India
e-mail: mohammad.taufik@iiitdmj.ac.in

Prashant K. Jain

Mem. ASME
Mechanical Engineering Discipline,
PDPM Indian Institute
of Information Technology,
Design and Manufacturing Jabalpur,
Jabalpur 482005, Madhya Pradesh, India
e-mail: pkjain@iiitdmj.ac.in

1Corresponding author.

Manuscript received March 20, 2015; final manuscript received November 25, 2015; published online January 5, 2016. Assoc. Editor: Z. J. Pei.

J. Manuf. Sci. Eng 138(6), 061002 (Jan 05, 2016) (11 pages) Paper No: MANU-15-1125; doi: 10.1115/1.4032193 History: Received March 20, 2015; Revised November 25, 2015

Surface roughness prediction studies in fused deposition modeling (FDM) process are usually based on a perimeter profile of each deposited layer. This study categorizes three types of build edge profile composed of perimeter, raster, and combination of both layer deposition patterns, which have been considered to reduce the predictive error of roughness models. Furthermore, an innovative approach based on combination of theoretical and empirical methods is used to analyze and predict the randomness in the geometry of build edge profiles. The same methodology is used to model the roughness profile and surface roughness behaviors. The proposed models have been tested for robustness against varying build orientations and with data available in the existing literature. The robustness of the proposed models is compared with the existing models. The results clearly demonstrate that the proposed models are very useful in reducing prediction errors.

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Figures

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Fig. 2

Build edge profile of a layered-shape prototype at different build orientations (α3 > α2 > α1): (a) perimeter, (b) perimeter and raster, and (c) raster

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Fig. 3

Geometry of build edge profiles: (a) simplified situation, (b) actual situation, and (c) profile modeling of simplified peaks

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Fig. 4

Schematic representation of (a) simplified and (b) experimental surface profiles by offsetting the reference (mean) line

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Fig. 5

Modeling of the perimeter-based build edge profile

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Fig. 6

Modeling of the raster-based build edge profile

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Fig. 10

Histogram graph for (a) percentage of height (b) percentage of base length

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Fig. 11

Labeling of surface roughness measurement locations (1–13) on the test parts: (a) pyramid, (b) femur bone, and (c) truncheon

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Fig. 12

Experimental and fitted build edge profiles of FDM part, layer thickness: 0.254 mm

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Fig. 13

Surface roughness prediction models for the experimental data

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Fig. 9

(a)–(c) Microscopic images of build edge profiles under the three build orientation conditions. (d)–(f) Roughness profile of the corresponding build edge profiles.

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Fig. 8

Front and top view of truncheon part

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Fig. 7

Representation of combined build edge profile

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