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FDM Optimization for Miniature Castings

This document discusses optimizing standard aluminum alloys and fused deposition modeling (FDM) techniques for miniature castings. It describes FDM technology, properties of polylactic acid filament commonly used in FDM, and challenges such as overhanging structures that require support structures. Common defects in FDM like temperature issues, nozzle clogging, and vibration are outlined. Methods to improve bed adhesion, prevent intermediate fusion shock, and explore the influence of nozzle geometry are proposed. The document concludes by discussing applications like rapid tooling for match plate and mold making, and casting.

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Parkavi KG
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9 views30 pages

FDM Optimization for Miniature Castings

This document discusses optimizing standard aluminum alloys and fused deposition modeling (FDM) techniques for miniature castings. It describes FDM technology, properties of polylactic acid filament commonly used in FDM, and challenges such as overhanging structures that require support structures. Common defects in FDM like temperature issues, nozzle clogging, and vibration are outlined. Methods to improve bed adhesion, prevent intermediate fusion shock, and explore the influence of nozzle geometry are proposed. The document concludes by discussing applications like rapid tooling for match plate and mold making, and casting.

Uploaded by

Parkavi KG
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Optimisation of standard Aluminium alloy

and FDM technique for miniature castings

PRAGADEESH RAMU, SRI MUGUNDAN V,


Final year Students,
Department of Mechanical Engineering,
S.A. Engineering College, Chennai, India.
2

About FDM technology

▫ Fused Deposition Modeling is an additive manufacturing


process that belongs to the material extrusion family

▫ In FDM, an object is built by selectively depositing melted


material in a pre-determined path layer-by-layer

▫ The materials used are thermoplastic polymers and come


in a filament form
3
4

Polylactic Acid
properties

Melting point : 180 degree Celsius

Density : 1.210–1.430 g·cm−3

Filament diameter : 1.75mm


5
Overhanging structures

Challenges in
FDM

Requires support
structures leading to :

• Increased printing
time
• Wastage of material
• Poor surface finish
Over hanging structure prevention through design

6
7

• Operating temperatures
Common • Extrusion temperature
defects in FDM • Substrate temperature
• Print speed
• Extrusion rate
• Printer calibration
• Placement of the print platform and position nozzle
• Nozzle clogging
• Disrupted material flow
• Loss of adhesion to the print platform,
• Vibration
• Inaccurate adjustments of printer settings
8

Bed Adhesion

Cause and effects

• The bed surface (PET


tape, glass, or other
types)

• The material you are


printing in (PLA, ABS,
Nylon)

• And the substrate


temperature
DEFECTS IN FDM TECHNOLOGY

Elmer’s Adhesion glue Under extrusion Intermediate fusion shock

9
Disrupted material flow
Snapped Filament
Filament knot

Stripped Filament

10
Incorrectly Levelled Bed

11
Nozzle block

Nozzle shear on Bed

12
Influence of NOZZLE geometry

TYPE D TYPE B

13
14

• Intermediate fusion shock


Unexplored
areas • Rapid gas expansion in PLA filament

• Deposition on and without touching the


build plate

• Nozzle geometry

• Extrusion body assembly


NOZZLE GEOMETRY

TYPE A TYPE B TYPE C TYPE D

15
EXTRUSION BODY ASSEMBLY
Extrusion body length
Modified body length

Gas expansion in track


leading to popping & gap
in print

16
CURA UI
Optimization by tweaking
control parameters

Pronterface UI

17
% DENSITY VS STRENGTH % DENSITY VS SPEED

LAYERS VS
NUMBER OF LAYERS VS COST QUALITY
18
19
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Rapid Tooling

Application of
our work

Match Plate Mould


Printing Making

Casting
AC4B CHEMICAL COMPOSITION

Symbol
of type
Cu Si Mg Zn Fe Mn Ni Ti Pb Sn Cr Al
2.0 7.0 Rem
AC4B 0.50 1.0 1.0 0.50 0.35 0.20 0.20 0.10 0.20
to to ainde
max. max. max. max. max. max. max. max. max.
4.0 10.0 r

Symbol
Cu Si Mg Zn Fe Mn Mg Ti Pb Sn Cr Al
of type
Rem
0.2 7.5 0.45 0.1 0.2 0.1 0.20 0.20 0.10 0.20
AC4B 0.45 ainde
max max max max max max max. max. max. max.
r
Tensile Test Sample Specification Tensile Test Sample Location

All samples assumed to be cut to “Sub size Specimen” dimensions from the ASTM E8 Standard

Location 1 Location 2

SPECIMEN INTERFACE LONGITUDINAL FRONT FACE


RESULT COMPARISON
Filling temperature with uniform even gradient
Solidification Result
Porosity Result
27
CONCLUSION

28
Thanks!
Curious to hear your questions

29
30

Credits

We would like to thank the management and


organizers of Madras Institute of Technology
for granting us this opportunity

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