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Correlation between printing parameters and residual stress in additive manufacturing: a numerical simulation approach

Alzyod Hussein, Ficzere Péter

Production Engineering Archives

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2023

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Vol. 29, Iss. 3

279-287

EN

Fused Deposition Modeling (FDM) is a widely used 3D printing technology that can create a diverse range of objects. However, achieving the desired mechanical properties of printed parts can be challenging due to various printing parameters. Residual stress is a critical issue in FDM, which can significantly impact the performance of printed parts. In this study, we used Digimat-AM software to conduct numerical simulations and predict residual stress in Acrylonitrile Butadiene Styrene (ABS) material printed using FDM. We varied six printing parameters, including printing temperature, printing speed, and infill percentage, with four values for each parameter. Our results showed that residual stress was positively correlated with printing temperature, printing speed, and infill percentage, and negatively correlated with layer thickness. Bed temperature did not have a significant effect on residual stress. Finally, using a concentric infill pattern produced the lowest residual stress. The methodology used in this study involved conducting numerical simulations with Digimat-AM software, which allowed us to accurately predict residual stress in FDM-printed ABS parts. The simulations were conducted by systematically varying six printing parameters, with four values for each parameter. The resulting data allowed us to identify correlations between residual stress and printing parameters, and to determine the optimal printing conditions for minimizing residual stress. Our findings contribute to the existing literature by providing insight into the relationship between residual stress and printing parameters in FDM. This information is important for designers and manufacturers who wish to optimize their FDM printing processes for improved part performance. Overall, our study highlights the importance of considering residual stress in FDM printing, and provides valuable information for optimizing the printing process to reduce residual stress in ABS parts.

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Prediction of the influence of printing parameters on the residual stress using numerical simulation

Alzyod Hussein, Ficzere Péter

System Safety : Human - Technical Facility - Environment

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2022

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Vol. 4, nr 1

150-156

EN

Fused Deposition Modeling is an additive manufacturing technology that is used to create a wide range of parts and applications. Along with its benefits, there are some challenges regarding the printed parts' mechanical properties, which are associated with printing parameters like layer thickness, printing speed, infill density, printing temperature, bed temperature, infill pattern, chamber temperature, and printing orientation. One of the most crucial challenges in additive manufacturing technology is the residual stress, which significantly affects the parts like fatigue life, cracks propagation, distortions, dimensional accuracy, and corrosion resistance. Residual stress is hard to detect in the components and sometimes is costly to investigate. Printing specimens with different parameters costs money and is timeconsuming. In this work, numerical simulation using Digimat-AM software was employed to predict and minimize the residual stress in printed Acrylonitrile Butadiene Styrene material using Fused Deposition Modeling technology. The printing was done by choosing six different printing parameters with three values for each parameter. The results showed a significant positive correlation between residual stress and printing temperature and infill percentage and a negative correlation with layer thickness and printing speed. At the same time, we found no effect of the bed temperature on the residual stress. Finally, the minimum residual stress was obtained with a concentric infill pattern.

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Influence of printing direction on 3D printed ABS specimens

Markiz Nassim, Horváth Eszter, Ficzere Péter

Production Engineering Archives

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2020

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Vol. 26, Iss. 3

127--130

EN

In the recent years, additive manufacturing became an interesting topic in many fields due to the ease of manufacturing complex objects. However, it is impossible to determine the mechanical properties of any additive manufacturing parts without testing them. In this work, the mechanical properties with focus on ultimate tensile strength and modulus of elasticity of 3D printed acrylonitrile butadiene styrene (ABS) specimens were investigated. The tensile tests were carried using Zwick Z005 loading machine with a capacity of 5KN according to the American Society for Testing and Materials (ASTM) D638 standard test methods for tensile properties of plastics. The aim of this study is to investigate the influence of printing direction on the mechanical properties of the printed specimens. Thus, for each printing direction ( and ), five specimens were printed. Tensile testing of the 3D printed ABS specimens showed that the printing direction made the strongest specimen at an ultimate tensile strength of 22 MPa while at printing direction it showed 12 MPa. No influence on the modulus of elasticity was noticed. The experimental results are presented in the manuscript.