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J. Santhakumar ¹, Rishabh Maggirwar ¹, Srinivas Gollapudi ¹, S. Karthekeyan ¹, Naveen Kalra ¹

Affiliations
1 Department of Mechanical Engineering, SRM University,Kattankulathur, Chennai - 603203, Tamil Nadu, IN

Abstract

Objectives: In this research, enhancement of Impact Strength is done using Polycarbonate material by Optimizing the FDM (Fused Deposition Modeling) Process Parameter. Methods/Statistical Analysis: This study features four important process parameters namely layer thickness, build orientation, raster angle and raster width whose influence on Impact Strength is studied. Experiments were conducted based on Taguchi Design of Experiments methodology. The current work finds out the optimum parameter settings required to obtain maximum impact strength on Polycarbonate Material. Analysis of Variancetest (ANOVA) was performed to find the most influencing process parameter on Impact strength. A confirmatory test using the optimum process parameters was also carried out. Findings: It was found that all four parameters interact collectively with each other to obtain variation in Impact Strength values. Layer thickness influences Impact Strength the most as compared to the other considered process parameters. The results of the study show that the value of Impact strength corresponding to the optimum input parameters of layer thickness, 0.254 mm; build orientation, 30°; raster width, 0.904 mm and raster angle 60°, was found to be 68.4J/m. The findings of the confirmatory test were very close and in good agreement. Applications/Improvements: The machinists and engineers would be benefitted by selecting the optimized values for enhancing the impact strength of FDM Built parts.

Keywords

Build Orientation, Fused Deposition Modeling, Impact Strength, Layer Thickness, Rapid Prototyping, Raster Angle, Raster Width.

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J. Santhakumar ¹, T. Rajasekaran ¹, Einstein Johnson ¹

Affiliations
1 Department of Mechanical Engineering, SRM University, Kattankulathur - 603203, Tamil Nadu, IN

Abstract

Objective: This paper presents the research work done in Pocket milling operation using Stainless steel 316 materials. The most critical process parameters namely, Coating thickness (μm), Depth of Cut [DOC] (mm), Spindle Speed [SS] (rev/ min) and Feed Rate (mm/min) are taken into consideration to improve the quality of the output characteristics. The required output characteristics are Cycle time (min), Surface quality measurement, i.e., Roughness of the surface (Ra), Wear of the Tool (mm), Microhardness (HV) and Material Removal Rate (mm3/min). Methods/Analysis: The Taguchi method was used to tabulate the Design of experiments (DOE) of L9 orthogonal array. According to the study, the required Material Removal Rate is considered ‘higher the better’ and other required output characteristics are ‘lower the better.’ To determine to a most significant process parameter, Taguchi’s grey relation analysis is used. To determine the significance and shift of each parameter to the total variation observed, Signal to Noise Ratio (S/N) was used. The contributions of each process parameters to obtain the required output characteristics are studied. Findings: From the grey relation grade, the highest maximum – minimum value shows that the depth of cut is the most influential input parameter for the obtained output characteristics. The optimum input parameters are tool coating thickness of 10 μm, the speed of the spindle being 2500 rev/min, feed rate being 1000 mm/min and depth of cut being 0.7 mm. A verification test was performed conducive to determine the veritableness of the obtained optimal input parameters. The test proves that the optimum input process variables satisfy the required output characteristics for pocket milling operation in AISI Stainless Steel 316 material.

Keywords

Coating Thickness, Design of Experiments (DOE), Grey Relational Analysis, Material Removal Rate (MRR), Signal to Noise Ratio.

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