Surface Characterization of Three-Dimensional Printed Fiber-Reinforced Polymer Following an In-Process Mechanical–Chemical Finishing Method

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Journal of Manufacturing Science and Engineering-transactions of The Asme Pub Date : 2023-04-11 DOI:10.1115/1.4062146
Aman Nigam, Bruce L. Tai
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Abstract

Abstract Fiber-reinforced polymer (FRP) additive manufacturing has transformed fused filament fabrication (FFF) by manufacturing products with excellent mechanical characteristics. However, the surface finish and dimensional characteristics of printed FRP parts are typically poor due to protruding fibers and the stair-stepping effect. This parametric study examined an in-process combined mechanical plus chemical finishing technique to improve the surface finish of FRPs manufactured through FFF. This process is particularly useful for internal or complex features that cannot be otherwise finished after printing. In this work, a custom-built three-axis machine with printing, machining, and chemical finishing capabilities was used for the experiments. The effect of mechanical finishing on surface characteristics was first quantified using chip load and spindle speed as independent parameters. Following that, chemical treatment was performed on the already machined surface at two pressing depths (PD), which control the normal contact force acting on the surface. The best surface characteristics were observed at a low chip load of 0.007 mm and a moderately high spindle speed of 20,000 rpm. After chemical treatment using a lower PD, a surface roughness reduction was observed (from 8.041 to 4.988 µm). Increased PD led to even lower Ra values (from 4.988 to 3.538 µm) due to the enhanced fiber encapsulation phenomenon. Finally, the dimensional analysis revealed that the final combined finished samples had less than 1%-dimensional error (0.05 mm), which is an order of magnitude less than the typical error in FFF-printed parts (0.5 mm). This study provides means to conduct finishing in an additive manufacturing environment to reduce the time, labor, and cost associated with post-processing.
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三维打印纤维增强聚合物在加工过程中机械化学整理方法后的表面表征
摘要纤维增强聚合物(FRP)增材制造通过制造具有优异力学特性的产品,改变了熔融长丝制造(FFF)。然而,由于纤维突出和台阶效应,打印FRP部件的表面光洁度和尺寸特性通常较差。本参数研究考察了一种过程中机械加化学综合整理技术,以提高通过FFF制造的frp的表面光洁度。这个过程对内部或复杂的特征特别有用,否则不能在打印后完成。在这项工作中,使用了一台定制的三轴机器,具有印刷,加工和化学整理功能。首先以切屑负荷和主轴转速为独立参数,量化了机械精加工对表面特性的影响。然后,在两个压制深度(PD)下对已经加工的表面进行化学处理,PD控制作用在表面上的法向接触力。在0.007 mm的低切屑负载和20,000 rpm的中高主轴转速下,观察到最佳的表面特性。使用较低PD进行化学处理后,观察到表面粗糙度降低(从8.041µm降至4.988µm)。由于增强的光纤封装现象,PD增加导致Ra值更低(从4.988降至3.538µm)。最后,尺寸分析表明,最终组合成品样品的尺寸误差小于1% (0.05 mm),这比fff打印部件的典型误差(0.5 mm)小一个数量级。本研究提供了在增材制造环境中进行精加工的方法,以减少与后处理相关的时间、劳动力和成本。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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