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Improving the Surface Quality of 3D printed Parts by FFF using Laser Process

Mousavi Bafrouei, Morteza | 2024

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 57259 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Movahhedy, Mohammad Reza
  7. Abstract:
  8. The fused deposition modeling (FDM) process is an additive manufacturing technique that builds parts layer by layer. Unique advantages such as simplicity of operation, the ability to use a wide range of durable and stable polymer materials, and the ability to produce parts with complex geometry in minimal time and cost compared to other additive manufacturing methods have made this process highly attractive in recent years. However, parts printed with this process suffer from low surface quality and poor dimensional accuracy due to the layered construction. High surface roughness limits the application of these parts in many fields such as aerospace and medicine where precision and high surface quality are required. Laser polishing is an emerging industrial process that can improve surface quality. Compared to traditional polishing methods, it has many notable features, including process controllability, no tool or material wear, and less processing time for complex and delicate parts. Proper selection of laser parameters greatly influences the cost and time of surface finishing for parts. In the present study, the effects of four parameters: laser power, scanning speed, laser beam overlap, and printing angle on the surface roughness of parts made by this process were investigated. Acrylonitrile butadiene styrene polymer was used to make test samples. To examine the effects of main factors and interactions between factors, a full factorial design method considering the mentioned four parameters at three levels was employed for experimental design. The results of the experiments were analyzed using MINITAB software. Additionally, analysis of variance tables were prepared to determine the influence of each parameter and their interactions, and various graphs were obtained. Based on the results of this research, laser power and printing angle were identified as the most influential parameters on the surface roughness of parts manufactured by fused deposition modeling. In the best case, the surface roughness improved by 84%. Using statistical regression modeling, the relationship between input factors and output parameters was determined. Finally, a mathematical model for predicting surface roughness based on input factors was presented
  9. Keywords:
  10. Additive Manufacturing ; Surface Roughness ; Surface Treatment ; Fused Deposition Modeling (FDM) ; Laser Polishing ; Three Dimentional Printing

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