Ultrasonic assisted 3D printing to improve printed parts surface finish

Samsudin, Puteri Nurul Syaza Syahirah (2018) Ultrasonic assisted 3D printing to improve printed parts surface finish. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Fused Deposition Modeling (FDM) has given several benefits such as it can utilize less expensive material and has free-form design characteristic. Although, FDM had offers great opportunity to have better improvement in the future technologies, it also has several limitations such as seam lines appear between layer and the production of excess material residue on the parts surface. The implementation of ultrasound frequency had been applied in numerous traditional machining and it had given a positive result in getting better surface roughness. However, from the literature review there is no investigation that has been made on the application of ultrasonic frequency for additive manufacturing (AM). This research documented an approach to obtaining better surface finish for FDM sample by applying ultrasonic vibration. There are three input parameters that were evaluated in this research which is layer thickness, frequency and fill of density correspond to it output respond which is surface roughness, Ra. The design of expert 6.0.8 software was used to design an experimental matrix by using Response Surface Methodology (RSM) analysis. Since the experiments for the surface roughness test were conducted, the experimental designs were valid as it was investigated within the ranges and optimum value parameters can be defined. From the experimental result, it is shown that the parameter of frequency and fill of density does not give any influence towards improvement of surface roughness. However, the optimum surface roughness can be occurred at 0.2 mm layer thickness. The optimize parameters on the effects of ultrasonic assisted FDM can be used in order to achieve better surface roughness.

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