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Investigation of Fused Filament Fabrication-Based Manufacturing of ABS-Al Composite Structures: Prediction by Machine Learning and Optimization

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Abstract

Additive manufacturing (AM) or fused filament fabrication (FFF) are used to fabricate innovative virgin/composite structures using thermoplastic polymers. FFF is one of the most fast-growing manufacturing processes of final products using polymer-based composites. This research uses acrylonitrile butadiene styrene (ABS) thermoplastic polymer as a matrix material to fabricate final-use products with aluminum (Al) metal spray reinforcement. To investigate the effect of Al spray reinforcement, three main input parameters; infill pattern (Triangle, line, and cubic), infill density (60, 80, and 100%), and the number of sprayed layers (2, 3, and 4) have been selected, and fractured strength have been studied using Taguchi L-9 orthogonal array. In addition, single objective, multi-objective, and prediction with machine learning (ML) have been performed on the samples’ flexural properties to select the best-optimized setting. Results of the study were supported with x-ray diffraction (XRD), optical and scanning electron microscope (SEM) fracture analysis.

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Acknowledgments

The authors are also highly thankful for technical assistance to the University Center for Research and Development, Chandigarh University, India, and the Center for Manufacturing Research, Guru Nanak Dev Engineering College, Ludhiana, India.

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Authors and Affiliations

  1. University Center for Research and Development, Chandigarh University, Mohali, Punjab, India

    Nishant Ranjan & Ranvijay Kumar

  2. Department of Mechanical Engineering, Chandigarh University, Mohali, Punjab, India

    Nishant Ranjan, Ranvijay Kumar & Sunpreet Singh

  3. Department of Mechanical and Production Engineering, Guru Nanak Dev Engineering College, Ludhiana, Punjab, 141006, India

    Raman Kumar

  4. Department of Information Technology, Guru Nanak Dev Engineering College, Ludhiana, Punjab, 141006, India

    Rupinder Kaur

  5. Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore

    Sunpreet Singh

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  1. Nishant Ranjan
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Correspondence to Raman Kumar.

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Ranjan, N., Kumar, R., Kumar, R. et al. Investigation of Fused Filament Fabrication-Based Manufacturing of ABS-Al Composite Structures: Prediction by Machine Learning and Optimization. J. of Materi Eng and Perform 32, 4555–4574 (2023). https://doi.org/10.1007/s11665-022-07431-x

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  • DOI: https://doi.org/10.1007/s11665-022-07431-x

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