Abstract

Additive manufacturing (AM) is an environmentally friendly process of constructing 3D objects by using Computer Aided Design (CAD) models. The material can be metals in powder form, thermoplastics, thermosets, ceramics, and more. AM is divided into seven main categories according to the American Society for Testing and Manufacturing (ASTM), and one of the most common types is material extrusion. In material extrusion, solid materials, most commonly thermoplastics, are preheated and extruded out of a nozzle from which the material is deposited layer by layer. Material extrusion is widely considered as one of the most user friendly and inexpensive 3D printers. Another common name for material extrusion is Fused Deposition Model (FDM). This paper examines five different parameters, the interaction between them, and the role that they have in affecting the final build quality of the printed model. The parameters understudy are infill density, infill pattern, wall thickness, layer height, and printing speed. The printing parameters of the samples shall undergo a Design of Experiment (DoE) approach that will utilize an L16 Taguchi with two replications, with each of the 5 building parameters having 4 levels. The samples will then be subjected to a tensile strength test of fixed parameters and test setup. The data shall be recorded up to the fracture point of the samples, and this data will be collected once the test is completed to plot the stress-strain curves of all samples providing a visual illustration of various mechanical properties: elastic modulus, yield point, strain at break, resilience, and Ultimate Tensile Strength (UTS). The analysis segment of the work will rely on Grey Relational Analysis (GRA) to rank the build parameters for the most optimal build. Taguchi is used later to analyze the data from another perspective, ranking the build parameters against each mechanical property in addition to suggesting the levels.

Publication Date

11-28-2022

Document Type

Master's Project

Student Type

Graduate

Degree Name

Engineering Management (ME)

Advisor

Adolf Acquaye

Advisor/Committee Member

Salman Pervaiz

Campus

RIT Dubai

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