Skip to main content
SpringerLink
Log in

Modelling micro geometrical profiles in fused deposition process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Fused deposition modelling is an established additive manufacturing technique for creating functional prototypes from three-dimensional computer-aided design models. Despite of the potential advantages of this technology, surface roughness is a substantial problem and some attempts have been made to predict the average roughness R a. As well known, the surface quality characterization of a part is not limited to R a but involves many other roughness parameters. The knowledge in advance of these parameters is a critical point especially in the product design stage both for rapid prototyping purpose and finished part manufacturing. In this work, a novel approach aimed to the geometrical description of roughness profile is reported. By means of an analytic formulation it is possible to calculate custom set of roughness parameters. An experimental analysis, based on design of experiments technique, is carried out to investigate the effects of several factors on shape profile. The achieved results permit to define the domain in which the presented model depends only on two parameters. A profilometric analysis has been performed on specimens properly designed to validate the method. Statistical tests show a good accordance with predicted values for the made assumptions and the calculated roughness parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Gebhardt A (2003) Rapid prototyping. Hanser, Munich

    Google Scholar 

  2. Chua CK, Leong KF, Lim CS (2010) Rapid prototyping: principles and applications, 3rd edn. World Scientific, Singapore

    Book  Google Scholar 

  3. Wholers TT (2006) Wohlers report 2006: rapid prototyping & manufacturing state of the industry annual worldwide progress report. Colorado, USA

    Google Scholar 

  4. Jin Y, Zhang J, Wang Y, Zhu Z (2009) Filament geometrical model and nozzle trajectory analysis in the fused deposition modeling process. J Zhejiang Univ Sc 10:370–376

    Article  Google Scholar 

  5. Leong KF, Chua CK (1996) A study of stereolithography file errors and repair part 1—generic solutions. Int J Adv Manuf Technol 12:407–414

    Article  Google Scholar 

  6. Leong KF, Chua CK (1996) A study of stereolithography file errors and repair part 2—special cases. Int J Adv Manuf Technol 12:415–422

    Article  Google Scholar 

  7. Lee BH, Abdullah J, Khan ZA (2005) Optimization of rapid prototyping parameters for production of flexible ABS object. J Mater Process Technol 169:54–61

    Article  Google Scholar 

  8. Huang X, Ye C, Wu S, Guo K, Mo J (2009) Sloping wall structure support generation for fused deposition modelling. Int J Adv Manuf Technol 42:1074–1081

    Article  Google Scholar 

  9. Chang DY, Huang BH (2011) Studies on profile error and extruding aperture for the RP parts using the fused deposition modeling process. Int J Adv Manuf Technol 53:1027–1037

    Article  Google Scholar 

  10. Galantucci LM, Lavecchia F, Percoco G (2009) Experimental study aiming to enhance the surface finish of fused deposition modeled parts. CIRP Ann Manuf Technol 58:189–192

    Article  Google Scholar 

  11. Pandey PM, Reddy NV, Dhande SG (2003) Improvement of surface finish by staircase machining in fused deposition modelling. J Mater Process Technol 13:323–331

    Article  Google Scholar 

  12. Vasudevarao B, Natarajan DP, Henderson M, (2000) Sensitivity of RP surface finish to process parameter variation. Proceedings of solid free form fabrication. Austin, USA: 252–58

  13. Anitha R, Arunachalam S, Radhakrishnan P (2001) Critical parameters influencing the quality of prototypes in fused deposition modelling. J Mater Process Technol 118:385–388

    Article  Google Scholar 

  14. Pandey PM, Reddy NV, Dhande SG (2003) Real time adaptive slicing for fused deposition modeling. Intern J Mach Tools & Manuf 43:61–71

    Article  Google Scholar 

  15. Campbell RI, Martorelli M, Lee HS (2002) Surface roughness visualization for rapid prototyping models. Computer-Aided Design 34:717–725

    Article  Google Scholar 

  16. Ahn D, Kim H, Lee S (2009) Surface roughness prediction using measured data and interpolation in layered manufacturing. J Mater Process Technol 209:664–671

    Article  Google Scholar 

  17. Perez CJL, Vivancos J, Sebastiàn MA (2001) Surface roughness analysis in layered forming processes. Precis Eng 25:1–12

    Article  Google Scholar 

  18. Montgomery DC (2009) Design and analysis of experiment, 7th edn. Wiley, New Jersey

    Google Scholar 

  19. Gadelmawla ES, Koura MM, Maksoud TMA, Elewa IM, Soliman HH (2002) Roughness parameters. J Mater Process Technol 123:133–145

    Article  Google Scholar 

  20. ISO 4287 (1997) Geometrical product specifications (GPS)—surface texture: profile method—terms, definitions and surface texture parameters, pp. 1–25

  21. Boschetto A, Veniali F (2010) Intricate shape prototypes obtained by FDM. J Material Forming 3:1099–1102

    Article  Google Scholar 

  22. ISO/DTS 16610–22 (2006) Geometrical Product Specifications (GPS)–Filtration–Linear profile filters: Spline filters, pp. 1–6

  23. Fowlkes WY, Creveling CM (1995) Engineering methods for robust product design. Addison-Wesley, Boston

    Google Scholar 

  24. Montgomery DC, Runger GC (2003) Applied statistics and probability for engineers, 3rd edn. Wiley, New York

    Google Scholar 

  25. Rawlings JO, Sastry GP, Dickey DA (2001) Applied regression analysis: a research tool. Springer, New York

    Google Scholar 

  26. Burnham KP, Anderson DR (2002) Model selection and multimodel inference: a practical information-theoretic-approach, 2nd edn. Springer, New York

    MATH  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Dipartimento di Ingegneria Meccanica e Aerospaziale, Sapienza Università di Roma, 00184, Roma, Italy

    A. Boschetto, V. Giordano & F. Veniali

Authors
  1. A. Boschetto
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. V. Giordano
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. F. Veniali
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to V. Giordano.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Boschetto, A., Giordano, V. & Veniali, F. Modelling micro geometrical profiles in fused deposition process. Int J Adv Manuf Technol 61, 945–956 (2012). https://doi.org/10.1007/s00170-011-3744-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-011-3744-1

Keywords

Search

Navigation