A preliminary research on development of a fibre composite, curved FDM system

A PRELIMINARY RESEARCH ON DEVELOPMENT OF A FIBER-COMPOSITE, CURVED FDM SYSTEM LIU YUAN (B. Eng.) A THESIS SUBMITTED FOR THE DEGREE OF MASTERS OF ENGINEERING DEPARTMENT OF MECHANICAL ENGINEERING NATIONAL UNIVERSITY OF SINGAPORE 2008 Acknowledgements First and foremost I would like to express my sincere thanks and appreciation to my supervisor, Associate Professor Ian Gibson, for guidance, for his involvement in this research, for the technical discussions and particularly for his support throughout the course of my Master studies. I would not have finished this thesis without his support and drive Thanks to my colleague, Dr. Savalani Monica Mahesh, for the suggestion and discussion with her at the research project. I am also very grateful to research engineer Anand Nataraj and fellow post-graduate student Muhammad Tarik Arafat for encourage and discussion in study. I would also like to thank Advanced Manufacturing Laboratory (AML) and Laboratory for Concurrent Engineering and Logistics (LCEL) for providing facility to complete my research. Last but no least, I would like to express my deep sense of gratitude to my parents, for the financial and spiritual support and encouraged me throughout this difficult but exciting journey. Also, some of this work was funded by the MOE grant “Curved Fused Deposition Modelling”. i Table of Contents Acknowledgements . i Table of Contents .ii Summary . iv List of Figures v List of Tables vii List of Papers viii Chapter Introduction . 1.1 Rationale of Rapid Prototyping 1.1.1 Stereolithography (SLA) 1.1.2 Selective Laser Sintering (SLS) . 1.1.3 Laminated Object Manufacturing (LOM) . 1.1.4 Fused Deposition Modeling (FDM) . 1.1.5 Ink-jet deposition processes (ZCorp 3DP, Solidscape and Objet machines) . 10 1.1.6 Ballistic Particle Manufacture (BPM) . 13 1.1.7 Metal powder systems 14 1.1.8 Composite materials in RP . 15 1.2 Rapid Manufacturing 16 1.2.1 Geometric freedom 17 1.2.2 Materials 17 1.2.3 Elimination of tooling 18 1.3 The objectives of the thesis . 18 Chapter Overview of Curved-FDM 21 2.1 Hardware design . 24 2.1.1 The basic of screw design 25 2.1.2 Design variables . 26 2.2 Material selection 27 2.3 Discussion . 33 2.3.1 Benefits 33 ii 2.3.2 Barriers: 34 2.4 Conclusion 35 Chapter Process Parameters . 36 3.1 Process variables . 37 3.2. Build parameter considerations 38 3.3 Introduction of software 40 3.5. Design of experiment . 43 3.4 Experiment setup 45 3.4.1 Materials 45 3.4.2 Extrusion temperature 46 3.4.3 Dispensing speed . 47 3.4.4 Envelop temperature 48 3.4.5 Cross hatch . 49 3.5 Experiment 49 3.5.1 Preparation of compressive specimens 50 3.5.2 Preparation of tensile specimens 50 3.5.3 Results 52 Chapter 3D Curvature . 59 Chapter Future Works . 65 Chapter Conclusion 69 References . 71 Appendices . 75 iii Summary A novel rapid prototyping technology incorporating a curved layer building style is being developed. The new process, based on fused deposition modeling (FDM), will be developed for improving the mechanical properties of layer manufactured structures. A short fibre reinforced composite is used to improve the mechanical properties of the FDM objects. A machine was built for efficient fabrication of shell structures using addition of curved layers. A detailed description will be made of the material properties and hardware for this new process. The development of the material for FDM filaments and accompanying process technology for curved layer fabrication will also be discussed. When making curved layer objects, high performance composites can improve the mechanical properties of FDM articles since the layers conform to the part geometry. Extensive experimentation has been done to find out the effect of fiber content in the filament and to see the effect of fibre orientation and distribution in the FDM parts. iv List of Figures Figure 1.1 Stereolithography process . Figure 1.2 Selective Laser Sintering process . Figure 1.3 Laminated Object Manufacturing process . Figure 1.4 Fused Deposition Modeling process . Figure 1.5 Process of Z Corp 3DP 11 Figure 1.6 process of photopolymer inkjet system . 13 Figure 1.7 Ballistic particle manufacturing 13 Figure 2.1 schematic diagram of the Curved-FDM 22 Figure 2.2 Comparative layer-based approach for building parts . 24 Figure 2.3 The sketch of extruder screw (James L. White, 2003) 26 Figure 2.4 The engineering drawing of screw 27 Figure 3.1 Curved-FDM . 36 Figure 3.2 slice control . 41 Figure 3.3 crosshatch setting . 41 Figure 3.4 round-way connected toolpath 42 Figure 3.5 3D modeling 43 Figure 3.6 Tensile Strength of different wood fiber contents and coupling agent in elevated Temperature. (Specimens: Filaments) 47 Figure 3.7 samples with one layer . 48 Figure 3.8 the side view of the sample . 49 Figure 3.9 2D drawing of the tensile specimen (4mm thickness) . 50 Figure 3.10 Long raster and short raster deposition patterns 51 Figure 3.11 Compressive modulus in 1% deformation with different wood fiber and coupling agent contents . 53 v Figure 3.12 Tensile strength of different wood fibers content and coupling agent in 180 ˚C. (Specimens: Dog-bone) 55 Figure 3.13 the SEM pictures of tensile fractured specimens (20%WF 3% MAPP 77% PP) . 56 Figure 3.14 20% WF,3% MAPP,77% PP (Pellet) 57 Figure 3.15 the upper is made of pp, the other is made of wood composite 57 Figure 4.1 Schematic diagram of respectively fabricating curved-FDM parts by using 3- & 5-axis control 61 Figure 4.2 a curved filament which is deposited in x-z plane 62 Figure 4.3 fabricating curved FDM parts with support 63 Figure 4.4 sample with two layers 63 Figure 5.1 the flow chart of sample production and testing . 67 vi List of Tables Table 2.1 Comparision between Curved-FDM and Stratasys FDM . 23 Table 2.2 Comparison of the properties of natural fibres and glass fibre . 32 Table 3.1 FDM process variables . 37 vii List of Papers Published papers: Liu Yuan and Ian Gibson, A Framework for Development of a Fiber-composite, Curved FDM System, Proceedings of the International Conference on Manufacturing Automation, Singapore, 2007 Ian Gibson, Savalani Monica Mahesh, Muhammad Tarik Arafat and Liu Yuan, The use of multiple materials in Rapid Prototyping, Proceedings of the third international conference on Advanced Research in Virtual and Rapid Prototyping, Leiria, Portugal, 2007 Ian Gibson, Liu Yuan and Anand Nataraj,Composites in RP, Proceedings of The Eighth Annual International Conference on Transportation Weight Reduction, Pilanesburg, Published by Rapid Prototyping Association of South Africa (RAPDASA), South Africa, 2007, CDROM version only. Paper in preparation: Savalani Monica Mahesh, Liu Yuan, Ian Gibson, Fused Deposition Modeling of Fibercomposites, Rapid Prototyping Journal, in preparation. viii Chapter Introduction Rapid prototyping is the name given to a group of related technologies that are used to fabricate physical objects directly from CAD data sources. These methods are unique in that they can produce objects by stacking materials in layers. Such systems, according to the unique process, also are named as additive fabrication, solid freeform fabrication, three dimensional printing and layer manufacturing. Five most common uses of rapid prototyping are: visualization, form and fit, product test, tooling and enduse parts（rapid manufacturing, or RM） (Carter，2001). So far RP technologies are most used by designers and engineers to better understand and communicate the designs as well as to make rapid tooling to produce those products. People from other disciplines also use RP technologies such as surgeons, architects, artists, etc. When the RP material is suitable, highly complicated shapes can be produced because of the nature of RP and often RP is referred to as providing ‘complexity for free’. In some cases, the RP part can be the final part, but typically the RP part is not strong or accurate enough, or some other material property is not suitable for the application (colour, translucency, thermal transfer, etc.). Presently most of the research work is directed toward developing new materials or processes which target on mechanical properties improvement of RP parts （Masood，1996） References Gibson, I., et al, The use of multiple materials in Rapid Prototyping, Proceedings of the third international conference on Advanced Research in Virtual and Rapid Prototyping, Leiria, Portugal, 2007, pp 51-56 Giles, Harold F, Extrusion topics, v.1: Single screw extrusion, twin screw extrusion, polymeric materials / Giles, Imprint Wm Andrew Pub, 2001 Gray, R.W., Baird, D.G., Bohn, J.H., Effects of processing conditions on short TLCP fiber reinforced FDM parts, Rapid Prototyping Journal, vol4, num1, pp. 14-25 Herrera-Franco, P.J. and Valadez-Gonza´lez, A., A study of the mechanical properties of short natural-fiber reinforced composites, Composites: Part B vol36, 2005.pp. 597–608 Hilmas, G.E., Lombardi, J.L., Hoffman, R.A. and Stuffle, K., Recent developments in extrusion freeform fabrication (EFF) utilizing non-aqueous gel casting formulations, Proceedings Solid Freeform Fabrication Symposium, University of Texas at Austin, 1996, pp 443-450 Hutmacher,D.W., Sittinger, M and Risbud, M.V, Scaffold-based tissue engineering : rationale for computer aided design and solid free-from fabrication systems. Trends Biotechnol., vol22, num7, 2004, pp.352-62 Klosterman, D., Chartoff, R., Osborne, N., Graves, G., Lightman, A., Han, G., Bezeredi, A. and Rodrigues, S., Curved Layer LOM of Ceramics and Composites, Solid Freeform Fabrication Symposium Proceedings, University of Texas at Austin, Austin, TX, August, 1998, pp. 671–680 Lombardi, J.L., Hoffman, R.A., Waters, J.A., Popovich, D., Souvenir, C., Boggavarapu, S. and Tennison, B., Issues associated with EFF & FDM ceramic filled feedstock formulation, Proceedings Solid Freeform Fabrication Symposium, University of Texas at Austin, 1997, pp. 457-464 72 References Lorrison, J. C., Goodridge, R. D., Dalgarno, K. W. and Wood, D. J., Selective Laser Sintering of Bioactive Glass-Ceramics, Proceedings Solid Freeform Fabrication Symposium, University of Texas at Austin, 2002, pp 1-8. Lee CS, Kimb SG, Kimb HJ, Ahnb SH, Measurement of anisotropic compressive strength of rapid prototyping parts, Journal of Materials Processing Technology, 2007, pp.187–188:627–30. Marcus, H.L. and Bourell, D.L., Adv. Mater. Process, Sept. 1993, pp.28–35 Masood, S. H., Intelligent rapid prototyping with fused deposition modeling, Rapid Prototyping Journal, vol2, num1, 1996, pp. 24–33 Matthews, F.L. and Rawlings, R.D, Composite Materials: Engineering and Science, 1994 Mohanty, A. K., Misra, M., Drzal, L. T., Natural Fibers, Biopolymers, and Biocomposites, 2005 Qi, G., Dai, C., Rangarajan, S., Wu, S., Danforth, S.C.,Safari, A. and Dandyopadhyay, A. , “Properties of RU955 Si3N4 filament for fused deposition of ceramics,” Proceedings Solid Freeform Fabrication Symposium, University of Texas at Austin, 1997, pp. 421-430 Rana, A.K., Mandal, A, Mitra, B. C., Jacobson, R. , Rowell, R., and Banerjee, A. N., Short Jute Fiber-Reinforced Polypropylene Composites: Effect of Compatibilizer, Journal of Applied Polymer Science, vol69, 1998, pp. 329–338 Rodriguez, J. F., Thomas, J. P. and Renaud, J. E., Characterization of the mesostructure of fused-deposition acrylonitrile-butadienestyrene materials, Rapid Prototyping Journal, vol6 , num3, 2000, pp. 175-185 Safari, A., Danforth, S.C., Panda, R.K., McNulty, T.F., Mohammadi, F. and Bandyopadhyay, A., Processing of novel piezoelectric transducers via SFF 73 References Proceedings Solid Freeform Fabrication Symposium, University of Texas at Austin, 1997, pp. 403-410 Sanadi, A.R., Caulfield, D. F., Jacobson, R. E., and Rowell, R. M., Industrial and Engineering Chemistry Research, vol34, 1995, pp.1889 Wallenberger, F. T., and Weston, N., natural fibers, plastics and composites, 2004 Wohlers, T., Obstacles to Rapid Manufacturing, 2006, http://wohlersassociates.com Wohlers. T., Wohlers’report 2006. Wang, T.M., Xi, J.T., Jin,Y., A model research for prototype warp deformation in the FDM process, Int J Adv Manuf Technol, vol33, 2007, pp. 1087–1096 White, Lindsay, J., Screw extrusion: science and technology, Imprint Munich; Cincinnati: Hanser, c2003. Zhong, W.H., short fiber reinforced composites for fused deposition modelling, Materials Science and Engineering A301, 2001, pp.125–130 Zhang, W., Design of Rapid Prototyping Manufacturing Systems and Principles and Applications of Control, Ph.D. Dissertation, Tsinghua University, 1997. www.compositesworld.com 74 Appendices Appendix: Scanning Electron Microscopy (SEM) Pictures 100% PP 75 Appendices 10% WF, 90% PP (Pellet) 10% WF, 90% PP (Pellet) 76 Appendices 20% WF, 80% PP (Pellet) 20% WF, 80% PP (Pellet) 77 Appendices 20% WF, 3% MAPP, 77% PP (Pellet) 20% WF, 3% MAPP, 77% PP (Pellet) 78 Appendices (Longitudinal) 20% WF, 80% PP (Longitudinal) 20% WF, 3% MAPP, 77% PP 79 Appendices 10% WF, 90% PP 10% WF, 90% PP 80 Appendices 10% WF, 90% PP 81 Appendices 10%WF 1% MAPP 89% PP 10%WF 1% MAPP 89% PP 82 Appendices 20%WF 1% MAPP 79% PP 20%WF 1% MAPP 79% PP 83 Appendices 20%WF 1% MAPP 79% PP 84 Appendices 20%WF 3% MAPP 77% PP 20%WF 3% MAPP 77% PP 85 Appendices 20%WF 3% MAPP 77% PP 86 Appendices Appendix: Engineering Drawings of the Extruder Title: screw DWG NO. Material: STAVAX SCALE 1:1 87 [...]... is that the advantages of materials only give a blueprint There are only a few dozens of RP/RM materials commercially available in the market, spread out over all classes of material such as plastics, metals and ceramics Compared to those available to standard manufacturing technologies, RP/RM material still has a long way to go 1.2.3 Elimination of tooling Theoretically, CAD directly drives all RP... in this case an industrial laser that is used to directly fabricate metal parts They can be used for either direct creation of a part or add material to existing components for Service and Repair applications In both cases one achieves a metallurgical bond as opposed to the mechanical bond of a weld The laser acts as a mixing device to melt some of the previous layer as it deposits They can deposit... Introduction fabricated for overhanging geometries and are later removed by breaking them away from the object A water-soluble support material which can simply be washed away is also available Advantages: The FDM process can build models from ABS and other plastics which are light and strong but relatively brittle compared with equivalent injection moulded plastics Colored filament is available and a single... same level of the parts made by conventional manufacturing technology Post-treatments, such as support material removal and hand-finishing, are required There are also size limitations at present which are more restrictive than those of standard manufacturing methods 1.2.2 Materials Using of multiple materials, composites and functional graded materials offers the potential to control the local geometric... the additive powders include aerospace grade aluminum, glass, and carbon-based particles 3D systems also offer a competitive range of composite materials for its SLS machines In addition, there is a composite material called Bluestone specially developed by 3D systems for the SLA process The material contains nano-sized ceramic particles that provide a means of improving stiffness, rigidity and heat... equivalent parts made using conventional processes Whilst there are distinct advantages in the use of RP, one factor hindering the development into RM is the fact that parts are generally weaker than their equivalents manufactured conventionally For example, FDM ABS parts are approximately 70% of the UTS that can be achieved using injection molding due to the gaps that will inevitably occur in parts... Introduction 1.1.3 Laminated Object Manufacturing (LOM) Profiles of object cross sections are cut from paper or other web material using a laser (Fig 1.3) Variations of this process may use a blade instead of a laser The paper is unwound from a feed roll onto the stack and first bonded to the previous layer using a heated roller which melts a plastic coating on the bottom side of the paper The profiles are... surface properties By adding different materials to each other via these methods can allow one to take advantage of dissimilar materials in an environment where one or the other would not normally be used The LENS process has excelled in the deposition of titanium and its alloys Operating in a vacuum environment it can deposit titanium and achieve equivalent mechanical properties to that of a cast... thermoplastic (Fig 1.7) BPM uses 3-D data about a solid model to position streams of material on a target 3-D objects are generated in a way that is comparable to how inkjet printers produce 2D images Like FDM and SLA, support structures are required for "unconnected" features The supports are deposited in a perforated pattern to facilitate removal Part material supports are made from water soluble wax... the laser beam strikes the surface of the liquid Once one layer is completely traced, it is lowered a small distance into the vat so that a thin amount of resin now covers the first layer and a second layer is traced right on top of the first The self-adhesive property of the material causes the layers to bond to one another and eventually form a complete, three-dimensional object after many such layers . Automation, Singapore, 2007 Ian Gibson, Savalani Monica Mahesh, Muhammad Tarik Arafat and Liu Yuan, The use of multiple materials in Rapid Prototyping, Proceedings of the third international conference. very grateful to research engineer Anand Nataraj and fellow post-graduate student Muhammad Tarik Arafat for encourage and discussion in study. I would also like to thank Advanced Manufacturing. conference on Advanced Research in Virtual and Rapid Prototyping, Leiria, Portugal, 2007 Ian Gibson, Liu Yuan and Anand Nataraj,Composites in RP, Proceedings of The Eighth Annual International Conference