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Experimental Research on the Dimensional and Geometrical Deviations of Features-of-Size Produced by Material Extrusion Processes

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Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems (FAIM 2023)

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

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Abstract

A major advantage of Additive Manufacturing (AM) processes is their ability to produce components with complex surfaces and sophisticated structures. However, several functional requirements of end-use AM parts, related to interchangeability and assemblability, are still strongly dependent on tightly toleranced Features-of-Size (FoS), as defined in current ISO-GPS standards. The paper presents an experimental approach for evaluating the dimensional and geometrical deviations of FoS produced by AM Material Extrusion processes (MEX) where the material is joined by thermal reaction bonding (MEX-TRB), such as Fused Deposition Modeling (FDM). A set of custom, primitive based test components are manufactured by low-cost and professional MEX-TRB printers, in different materials and orientations. The FoS linear and form deviations, as per ISO 14405-1 and ISO 1101, of the produced components are then evaluated by a Coordinate Measuring Machine (CMM). With the use of regression analysis, a statistical model is created, presenting and categorizing those defects. Finally, the development of a hybrid experimental/theoretical model for the prediction of linear and form deviations in MEX is presented and discussed.

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Authors and Affiliations

  1. School of Mechanical Engineering, National Technical University of Athens, Heroon Polytechniou 9, Zografou, 15780, Athens, Greece

    Christos Vakouftsis, Georgios Kaisarlis, Vasilios Spitas & Christopher G. Provatidis

Authors
  1. Christos Vakouftsis
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  2. Georgios Kaisarlis
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  3. Vasilios Spitas
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  4. Christopher G. Provatidis
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Corresponding author

Correspondence to Georgios Kaisarlis .

Editor information

Editors and Affiliations

  1. TEMA - Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Porto, Portugal

    Francisco J. G. Silva

  2. TEMA - Centre for Mechanical Technology and Automation, Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal

    António B. Pereira

  3. Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal

    Raul D. S. G. Campilho

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Vakouftsis, C., Kaisarlis, G., Spitas, V., Provatidis, C.G. (2024). Experimental Research on the Dimensional and Geometrical Deviations of Features-of-Size Produced by Material Extrusion Processes. In: Silva, F.J.G., Pereira, A.B., Campilho, R.D.S.G. (eds) Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems. FAIM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-38241-3_27

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  • DOI: https://doi.org/10.1007/978-3-031-38241-3_27

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-031-38240-6

  • Online ISBN: 978-3-031-38241-3

  • eBook Packages: EngineeringEngineering (R0)

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