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Research Papers

Modeling Machine Motion and Process Parameter Errors for Improving Dimensional Accuracy of Fused Deposition Modeling Machines

[+] Author and Article Information
Jiaqi Lyu

Department of Mechanical Engineering,
Stevens Institute of Technology,
Hoboken, NJ 07030
e-mail: Jlyu2@stevens.edu

Souran Manoochehri

Fellow ASME
Department of Mechanical Engineering,
Stevens Institute of Technology,
Hoboken, NJ 07030
e-mail: smanooch@stevens.edu

1Corresponding author.

Manuscript received April 18, 2018; final manuscript received August 17, 2018; published online October 5, 2018. Assoc. Editor: Zhijian (ZJ) Pei.

J. Manuf. Sci. Eng 140(12), 121012 (Oct 05, 2018) (8 pages) Paper No: MANU-18-1257; doi: 10.1115/1.4041328 History: Received April 18, 2018; Revised August 17, 2018

The dimensional accuracy of fused deposition modeling (FDM) machines is dependent on errors caused by processing parameters and machine motions. In this study, an integrated error model combining these effects is developed. Extruder temperature, layer thickness, and infill density are selected as parameters of this study for three FDM machines, namely, Flashforge Finder, Ultimaker 2 go, and XYZ da Vinci 2.0 Duo. Experiments have been conducted using Taguchi method and the interactions between processing parameters are analyzed. Based on the dimensional deviations between fabricated parts and the computer aided design (CAD) geometry, a set of coefficients for the integrated error model are calculated to characterize each machine. Based on the results of the integrated error model, the original CAD geometry is optimized for fabrication accuracy on each machine. New parts are fabricated using the optimized CAD geometries. Through comparing the dimensional deviations of parts fabricated before and after optimization, the effectiveness of the integrated error model is analyzed and demonstrated for the three FDM machines.

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Figures

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Fig. 1

The 3D artifact ((a) Geometry and (b) highlighted sampling points)

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Fig. 2

Interaction between parameters ((a) between extruder temperature and layer thickness, (b) between extruder temperature and infill density, and (c) between layer thickness and infill density)

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Fig. 3

The kinematic chain diagram of an FDM machine

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Fig. 4

Errors from processing parameters ((a) Errors from extruder temperature, (b) errors from layer thickness, and (c) errors from infill density)

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Fig. 5

Scale errors of the uncompensated and compensated models ((a) Scale error of X-axis, (b) scale error of Y-axis, and (c) scale error of Z-axis)

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Fig. 6

(a) Straightness error of Z-axis in X direction and (b) rotational error of Z-axis rotating along Y-axis

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