Failure Analysis and Mechanical Characterization of 3D Printed ABS With Respect to Layer Thickness and Orientation
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TECHNICAL ARTICLE—PEER-REVIEWED
Failure Analysis and Mechanical Characterization of 3D Printed ABS With Respect to Layer Thickness and Orientation Behzad Rankouhi . Sina Javadpour . Fereidoon Delfanian . Todd Letcher
Submitted: 3 April 2016 / Published online: 3 May 2016 Ó ASM International 2016
Abstract In contrast to conventional subtractive manufacturing methods which involve removing material to reach the desired shape, additive manufacturing is the technology of making objects directly from a computeraided design model by adding a layer of material at a time. In this study, a comprehensive effort was undertaken to represent the strength of a 3D printed object as a function of layer thickness by investigating the correlation between the mechanical properties of parts manufactured out of acrylonitrile butadiene styrene (ABS) using fused deposition modeling and layer thickness and orientation. Furthermore, a case study on a typical support frame is done to generalize the findings of the extensive experimental work done on tensile samples. Finally, fractography was performed on tensile samples via a scanning digital microscope to determine the effects of layer thickness on failure modes. Statistical analyses proved that layer thickness and raster orientation have significant effect on the mechanical properties. Tensile test results showed that samples printed with 0.2 mm layer thickness exhibit higher elastic modulus and ultimate strength compared with 0.4 mm layer thickness. These results have direct influence on decision making and future use of 3D printing and functional load bearing parts. Keywords 3D-printing Layer thickness Failure analysis Mechanical properties ANOVA Tukey HSD
B. Rankouhi S. Javadpour F. Delfanian T. Letcher (&) Mechanical Engineering, South Dakota State University, Dept PO Box 2219, Brookings, SD 57007-2201, USA e-mail: [email protected] B. Rankouhi e-mail: [email protected]
Introduction Complex geometries have always been out of reach for designers and manufacturers until the advent of additive manufacturing (AM) in the 1980s. ASTM defines the process as the ‘‘process of joining materials to make objects from three-dimensional (3D) model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies’’ [1]. AM is a very broad term which encompasses numerous methods such as binder jetting, direct metal laser sintering (DMLSÒ), fused deposition modeling (FDM), powder bed fusion, and stereolithography. The FDM technique is of particular interest due to its association with desktop 3D printers. The term 3D printing is often used synonymously with AM, but is more commonly associated with machines that are low end in price and/or overall capability [1] and it usually refers to polymers and non-metal materials. The emergence of this term in the early 2010s made the technology popular among engineers and mainstream in public. This popularity has led the technology to become one of the fastest growing technologies in the world [2]. The FDM pr
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