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P E R F O R M A N C E EVALUATION OF FD58 WATERWORKS SYSTEM f 0 8 - ASS PART

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KOLE J UNIVERSITI TEKNOLOGI TUN HUSSEIN ONN

BORANG PENGESAHAN STATUS TESIS*

JUDUL: PERFORMANCE EVALUATION OF FDM WATERWORKS SYSTEM FOR ABS PART

SESI PENGAJIAN: 2 0 0 6 / 2 0 0 7

Saya, OMAR MOHD FAIZAN BIN MARWAH ( H U R U F BESAR)

mengaku membenarkan tesis (PSM/Sarjana/Dokior Falsafah)* ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Kolej Universiti Teknologi Tun Hussein Onn. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian

tinggi. 4. **Sila tandakan (V)

SULIT

T E R H A D

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat T E R H A D yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

V TIDAK TERHAD

( T A N D A T A N G A N PENULIS)

Alamat Tetap:

NO 1 JLN M A N G G A , TMN MAJU

86400 PT. RAJA BATU P A H A T

J O H O R D A R U L TAKZIM

Tarikh: ^f / / J - / 2 C O &

Disahkan oleh

4/ (TANDATANG'AN PENYELIA)

P.M. IR. DR. SAPARUDIN ARIFFIN

Nama Penyelia

Tarikh: ,4//a.

CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila Iampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

• Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana M u d a ( P S M ) .

PERFORMANCE EVALUATION OF FDM WATERWORKS SYSTEM

FOR ABSPART

OMAR MOHD. FAIZAN B. MARWAH

A thesis submitted in fulfillment of the requirements for the award of the degree of

Master of Mechanical Engineering

Faculty of Mechanical and Manufacturing Engineering

Kolej Universiti Teknologi Tun Hussein Onn

NOVEMBER. 2006

"I declared that I read this project and in my point of view this project is qualified in

terms of scope and quality for purpose of awarding the

Master of Mechanical Engineering "

Signature

Supervisor

Date

If!

Assoc. Prof. Ir. Dr. Saparudin Ariffin

Z ^ / i x / a c r o C

V) Signature

Co Supervisor : Assoc. Prof. Dr. Safian Sharif

Date <4*-/1 jc

ii

"I declared that this thesis entitled "Performance Evaluation Of FDM Waterworks

System For ABS Part" is the result of my own research except as cited in references."

Signature :

Name of Candidate

Date

OMAR MOHD. FAIZAN B. MARWAH

iii

To my loving wife , Elmy Johana Mohamad and sons, Muhammad Hafiy Darwis and

Muhammad Harris Haikal, my family and friends

"My Success Is Yours Too "

iv

ACKNOWLEDGEMENT

The author would like to express his utmost appreciation and grateful to his

supervisor, Assoc. Prof. Ir. Dr. Saparudin from KUiTTHO and co-supervisor Assoc.

Prof. Dr. Safian from UTM, for their guidance, supervision, valuable opinion, priceless

ideas along the duration of this research and the heartfelt motivation during the

downhearted moment.

Alongside, I would also like to convey my appreciation to Mr. Hambali and Mr.

Kamarudin from KUTKM for them constructive support, Mr. Mokhtar Bin Abdul

Hamid from Rapid Manufacturing Laboratory for his guidance, Mr. An'Amur Rahman

Bin Yunos from Metrology Laboratory and Stratasys Inc. for its valuable information

on Fused Deposition Modeling process. Their valuable contribution had made this study

full of excitement.

My thanks to my loving family for their supports and sacrifice during the entire

moment of my study . Not forgetting my friends especially Erween , Nasuha and

Joharudin for their ideas and involvement during the discussion and ideas of the project.

V

ABSTRACT

Fused Deposition Modeling(FDM) is one of the Rapid Prototyping(RP)

Technologies to produces plastic prototypes from acrylonitrile butadiene styrene(ABS)

which has control over numerous processing variables that will impact the quality of the

fabricated part. The ability to select the optimal process parameters has been a major

concern for part quality improvement. This work was undertaken to determine parameters

which influence the part quality for FDM Waterworks Soluble Support(WSS) system

.The effect of these factors on FDM performance or response were investigated and the

optimum conditions of those responses were established. Design Of Experiments (DOE)

was used to perform the experiments. Experimental results were analysed by using

Minitab software to obtain the significant parameters and to optimize the setting.

Pareto Chart, Analysis of Variance(ANOVA), Main Effect plot and Regression were

employed to determine the significant parameters and to generates recommendations of

process variables setting and the associated predict build outcomes for FDM process .

Finally, validation tests were conducted to verify the model of each responses against the

actual results.

v i

ABSTRAK

Fused Deposition Modeling(FDM) merupakan salah satu daripada Teknologi

Pembuatan Deras untuk menghasilkan prototaip plastik daripada acrylonitrile butadiene

styrene(ABS) di mana terdapat pelbagai proses pembolehubah perlu dikawal yang akan

memberi kesan terhadap kualiti produk. Kemampuan untuk memilih parameter yang

optimum telah menjadi penting untuk memperbaiki kualiti sesuatu produk. Kajian ini

dijalankan untuk mengenalpasti parameter-parameter yang memberi kesan terhadap

kualiti produk untuk FDM Waterworks Soluble Support(WSS) sistem. Faktor atau respon

yang memberi kesan terhadap prestasi FDM dikaji dan keadaan optimum dapat

ditentukan untuk setiap respon tersebut. Design Of Experiments(DOE) digunakan untuk

menjalankan kerja eksperimen. Keputusan kajian dianalisis menggunakan perisian

Minitab dimana untuk mendapatkan parameter-parameter yang penting dan meramal

keadaan yang optimum. Rajah Pareto, Analysis of Variance(ANOVA),Main Effect Plot

dan Analisis Regression digunakan untuk memperolehi parameter penting dan memberi

rekomen dan ramalan terhadap produk yang dihasilkan di dalam proses FDM. Akhirnya ,

ujian pengesahan dijalankan untuk mengesahkan di antara model setiap respon dan

keputusan sebenar.

CONTENTS

CHAPTER SUBJECT PAGE

TITLE i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

CONTENTS vii

LIST OF FIGURES xi

LIST OF TABLES xiv

LIST OF SYMBOLS & ABBREVIATIONS xv

LIST OF APPENDIXES xvii

I PROJECT BACKGROUND 1

1.1 Introduction 1

1.2 Background Of Problems 3

1.3 Research Questions 4

1.4 Objectives Of The Project 4

1.5 Scopes Of The Project 5

1.6 Importance Of The Project 5

II LITERATURE REVIEW 7

2.1 Introduction to Rapid Prototyping 8

2.2 Fused Deposition Modeling 11

2.2.1 The principle Of FDM 12

2.2.2 Fused Deposition Modeling Process 14

2.2.3 Waterworks System 18

2.2.4 FDM Build Material 19

2.2.5 Advantages and Disadvantage of FDM 21

2.2.6 Advantages 21

2.2.7 Disadvantages 22

2.3 Product Defect Occurred In FDM 23

2.4 Process Parameter Consideration in FDM 27

2.4.1 Air Gap 27

2.4.2 Road Width 28

2.4.3 Layer Thickness 29

2.4.4 Raster Angle 29

2.4.5 Build/Raster Orientation 29

2.4.6 Tip Size 30

2.4.7 Base Oversize 30

2.5 Previous Research Based On Response Consideration 30

2.5.1 Surface Finish 31

2.5.2 Dimensional Accuracy 33

2.5.3 Built Time 35

2.5.4 Defect Analysis 37

2.6 Design Of Experiments (DOE)/Taguchi 37

2.6.1 Experimental Design 41

2.7 Literature Summary 43

Ill RESEARCH METHODOLOGY 44

3.1 Introduction 44

3.2 Overview of the Methodology 45

3.3 FDM System 48

3.3.1 Part Post Processing 50

3.4 Product Design 51

3.4.1 Pre-Processing (Converting CAD Files to STL) 52

3.5 Experimental Planning 53

3.5.1 Project Definition 54

3.5.2 Determine the Response Variables 54

3.5.2.1 Built Time 54

3.5.2.2 Surface Roughness 55

3.5.2.3 Dimensional Accuracy 56

3.5.2.4 Part Defects 58

3.5.3 Factor Level and Ranges 59

3.5.3.1 Fix Design Factor 60

3.5.4 Experimental Design 63

3.5.5 Perform The Experiment 64

IV RESULT AND DISCUSSION 66

4.1 Introduction 66

4.2 Experimental Result 67

4.3 Result Analysis Using Design Of Experiment 70

4.3.1 Surface Roughness 70


4.3.3 Built Time 73

4.3.4 Defect Measurement 75

4.4 Predicted of the Optimum Condition 76


4.4.2 Dimensional Accuracies 77

4.4.3 Built Time 79

4.4.4 Defect Condition 80

4.5 Validation of the DOE Analysis 82

4.6 Summary of DOE Analysis 84

4.7 Discussion on the Responses By Classical Method 85



4.7.3 Built Time 88

4.7.4 Part Defects 89

4.7.4.1 Type of Defect 91

4.8 Summary of Classical Method Analysis 98

V CONCLUSION, CONTRIBUTION AND 99

RECOMMENDATIONS

5.1 Conclusion 99

5.2 Contribution of this work 101

5.3 Future Recommendation 102

REFERENCES 103

APPENDIXES (A - E) 108

x i

LIST OF FIGURES

FIGURES PAGE

2.1 Classification of RP system 10

2.2 The Schematic View of FDM 13

2.3 Staircase Effect in RP Parts 23

2.4 Schematic View of Layered Boundaries Produced By Layered 24

Manufacturing Process

2.5 Tessellated or Faceted Surface Model, Chordal Error 24

2.6 Some Important Process Parameter 25

2.7 Slicing as mapping from the model of the layer domains 26

2.8 Air Gap 28

2.9 A Process Model 38

2.10a RP process chain 40

2.10b Transfer of CAD to RP System 40

3.1 Experiment Flow Chart 45

3.2 Methodology Overview and Result 47

3.3 FDM Prodigy Plus 50

3.4 Water Soluble Equipment and Waterworks Soluble Concentration 51

3.5 Product Design using Unigraphics NX2 52

3.6 STL File Setting 53

3.7 Surface Roughness Measuring Set 55

3.8 Direction of Measurement of Roughness 56

Xl l

3.9 Carl Zeiss Calypso Coordinate Measuring Machine 57

3.10 Measurement of the Dimensions 57

3.11 High Magnifying Measuring Microscope 58

3.12 Defect Inspection Area 59

3.13 Part Orientation 61

3.14 Model Tip 61

3.15 Modeler Setup 62

3.16 Factorial Design Menu 63

4.1 Pareto Chart for Surface Roughness 71

4.2 Pareto Chart for Dimensional Accuracies 72

4.3 Pareto Chart for Built Time 74

4.4 Pareto Chart for Defect Measurement 75

4.5 Main Effect Plot for Surface Roughness 76

4.6 Main Effect Plot for Dimensional Accuracies 78

4.7 Main Effect Plot for Built Time 79

4.8 Main Effect Plot for Defect 81

4.9 Surface Roughness Variation of Each Part 85

4.10 Overall Average Surface Roughness Measurement 86

4.11 Dimensional Variation of Each Features 87

4.12 Overall Dimensional Deviation 88

4.13 Built Time of Part Development 89

4.14 Defect Frequency for Every Features 90

4.15 Total Defect Frequency of Each Part 90

4.16 Type 1 Defect 91








x i v

LIST OF TABLES

TABLE PAGE

2.1 Essential Post-Processing Tasks for Different 18

RP Processes

2.2 Overall Literature Summary 43

3.1 FDM Prodigy Plus Specifications 49

3.2 Levels of Design Factors 60

3.3 Experiment Layout 64

4.1 Experimental Result For Surface Roughness 67

4.2 Experimental Result For Dimensional Accuracy 68

4.3 Experimental Result For Built Time 68

4.4 Experimental Result For Defect Measurement 69

4.5 Total Average Of Response 69

4.6 ANOVA Table For Surface Roughness 71

4.7 ANOVA Table For Dimensional Accuracies 73

4.8 ANOVA Table For Built Time 74

4.9 ANOVA Table For Defect Occurrence 75

4.10 Regression Analysis For Surface Roughness 77

4.11 Regression Analysis For Dimensional Accuracies 78

4.12 Regression Analysis For Built Time 80

4.13 Regression Analysis For Defect 81

4.14 Result Validation 83

4.15 Summary of Analysis on the Responses 98

5.1 Optimum Setting Condition 101

LIST OF SYMBOLS & ABBREVIATIONS

% Percent

(im Micro Meter

°C Degree Celsius

0 Diameter

ABS Acrylonitrile Butadiene Styrene

ANOVA Analysis Of Variance

BASS Breakaway Support System

BT Built Time

CAD Computer-Aided Design

cm Centimeters

CMM Coordinate Measuring Machine

DOE Design Of Experiment

DA Dimensional Accuracy

DF Defect

FDM Fused Deposition Modeling

LM Layered Manufacturing

LOM Laminated Object Manufacturing

m Meters

mm Millimeters

RM Rapid Manufacturing

RP Rapid Prototyping

RP&M Rapid Prototyping and Manufacturing

RT Rapid Tooling

RTV Room Temperature Vulcanizing

SFM Solid Free-Form Manufacturing

SGC Solid Ground Curing

SL Stereo lithography

SLA Stereolithography Apparatus

SLS Selective Laser Sintering

Std. Standard

.STL Stereolithography File

UG Unigraphics

WSS Water Soluble Support System

x v i i

LIST OF APPENDIXES

APPENDIX PAGE

A Engineering Drawing Of Part Experiment 108

B Printed Part Of Experiment 110

C Result Data Of Response 112

D Surface Roughness Data And Graph 117

E Dimensional Measurement Data 137

CHAPTER I

PROJECT BACKGROUND

1.1 Introduction

Rapid prototyping (RP) is a process in which a part is produced using layer by

layer deposition of material. It is an important technology as it has the potential of

reducing 30 to 50 % of the manufacturing lead time of the product even the product

complexity is very high (D.T. Pham and S.S. Demov., 2001 ). The RP cycle consists of

creation of geometric model using a solid modeler, determination of suitable deposition

orientation, slicing, generation of material deposition paths, part deposition and the post

processing operations. Most of the steps in RP are automatically driven; however part

deposition orientation is selected manually among the few options provided by the RP

software. Orientation for a part deposition on RP machine platform has a significant

effect on many key characteristics which will determine the final quality and cost of the

prototype (P.Alexander, et al., 1998).

23

Fused Deposition Modeling (FDM) is one of the major technique in developing

rapid prototypes or models. The FDM machine builds the part by extruding a semi-

molten filament through a heated nozzle in a prescribed pattern onto a platform. A

second nozzle may extrude a second material usually the support material if required.

When the first layer is completed, the platform move downwards by one layer thickness

and the building process repeats all over again. Once completed, the build model is

removed from the platform and removal of the support materials is done to obtain the

final part.

Recently , there are profoundly numerous possible parameters that can affect the

final quality of part using FDM. Altering the parameters will affects the character of the

resulting part. Determination of the proper significant parameters and optimum condition

has been a subject of research in the FDM area for a some time . Bharath, et al. (2000),

found the orientation and layer thickness as a significant parameters influence to surface

finish quality. Anitha, et al. (2001), concluded the layer thickness has been proved

influenced to surface roughness. Azanizawati, et al.(2003), have studied optimization for

build time and surface finish. They found that the layer thickness and orientation

influence to build time and orientation was the significant parameter affect to surface

roughness.

It is observed that most of previous work on produce better part quality has been

related to FDM BSS(Breakaway Support System).Not much work about orientation has

been directed to the FDM WSS system. Therefore, continue evaluation on performance

of part deposition orientation is a very essential as it effects build time, surface finish,

dimensional accuracy and defect occurrence. In this project, Design Of Experiments

(DOE) technique were used to study the influence of numerous parameters setting ,

optimum setting condition and predict the part quality outcomes .

3

1.2 Background Of Problems

Evaluation of part surface quality, geometrical accuracy and reduction in build

time is a major concern in RP technologies. Very few attempts (Nur Fazidah and Safian

Sharif, 2003) (D.T. Pham and S.S. Demov., 2001)(S.H. Masood, et al., 2001)

(K.Thrimurthulu, et al., 2004) have been conducted to evaluate performance of FDM

process which is more dominant as compared to Stereolithography(SL). Current support

removal system using BSS(Breakaway Support System) where the predecessor to

WSS(Waterworks Soluble Support) system that requires manual stripping of support

from the part surface seems to be less efficient as compared to WSS system in

obtaining optimum part quality within FDM technology .However in WSS system there

are lack of information settings and optimum parameters used on producing acceptable

part quality. Research on the FDM WSS system more limited as compared to Breakaway

Support System (BASS) where the WSS is the latest invention in FDM technology .

Currently, it was reported that most of FDM users use the default settings of the

various of parameters and others rely on the supplier recommendation or use trial and

error methods (Azanizawati, et al., 2003). These practices created waste of material and

time in achieving the optimum part quality . Furthermore, there are various methods in

determining significant parameters and to predict optimum condition of settings

including Adaptive Slicing, Classical Method and DOE(Design Of Experiment). A

stud}' on suitable method is required .

Hence there is a need to determine and produce a new prototype model for

identifying significant parameters and optimum settings within WSS system based

on various design criteria of responses through a suitable method . In addition

optimizing process parameters is one of the major concern in FDM research areas. Once

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