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Fused deposition modeling (FDM) is among the extensively used and the most economical additive manufacturing processes. Currently, the surface finish obtained for FDM additive manufactured parts are not at par with the current industrial application. To overcome the limitation of high surface roughness of 3D printed parts, a novel finishing techniq...
Contexts in source publication
Context 1
... primary finishing process used here for experimentation is 'facing' on a four jaw chuck lathe as shown in Fig. 4(a). Since facing is suitable only for a flat surface with limitations of the maximum dimension that chuck can hold, CNC milling process can be used for doing the primary finishing process on any kind of surface including the freeform surface. Furthermore, lapping is carried out before finally finishing with the BEMRF machine to lower the ...
Context 2
... 800, 1000, and 1200 were used to perform the lapping on the surface obtained after primary finishing process. This ensures the reduction of initial surface roughness in the order of few microns/nanometers. To avoid removal of the workpiece and mounting again on a lapping machine, the lapping was performed on the lathe machine itself as shown in Fig. 4(b). For a freeform surface manual free-hand lapping can be done after CNC machining to reduce the surface roughness and impart evenness in the surface. Initially, experimentation was done with water-based MR polishing fluid using three types of abrasives namely Alumina (Al 2 O 3 ) of mesh size 1000, Silicon carbide (SiC) of mesh size ...
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Citations
... Some researchers have concentrated on post-processing methods to address the challenges of surface roughness. Kumar et al. 19 attained a nano-level surface finish on polylactic acid (PLA) parts by combining a finishing by lathe machine, followed by finishing using ball end magnetorheological finishing. Kechagias et al. 20 investigated the impact of CO 2 laser processing on the surface quality of various FFF build parts. ...
Fused filament fabrication (FFF) is an increasingly popular three‐dimensional (3D) printing technology known for its ability to produce complex 3D models at a low‐cost using polymer materials. Despite its advantages, the poor surface finish and high layer resolution in FFF‐printed parts have hindered its wider adoption, particularly for applications requiring high transparency. Thus, the current study investigates the transparency evaluation of chemically post‐processed 3D‐printed transparent polylactic acid (PLA) parts, focusing on enhancing optical transparency. Fused Filament Fabrication was employed to produce transparent parts made from PLA filament, which were subsequently treated at various time settings using various solvents, including tetrahydrofuran (THF), chloroform or trichloromethane (TCM), and ethyl acetate (EA). This study examines the impact of chemical post‐processing on the surface roughness, transparency, mechanical properties, and dimensional accuracy of solvent treated parts. It has been found that the THF solvent with 40 s of immersion time resulted in a maximum transmittance of 74.66% and minimum surface roughness of 1.777 μm. Based on this finding a case study was also conducted to apply the findings of the current investigation to a practical application. The findings highlight the potential of chemical‐based post‐processing techniques to improve the optical properties of 3D printed PLA, offering a promising approach for applications in optics, medical devices, and consumer goods requiring transparent components.
Highlights
Effect of chemical post‐processing on 3D‐printed PLA parts was investigated.
Tetrahydrofuran, chloroform, and ethyl acetate were used as solvents.
Surface roughness, transparency, hardness, and dimensional accuracy were analyzed.
Reported a maximum transmittance of 74.66% and minimum surface roughness of 1.777 μm.
... Many ultra-precision finishing technologies exist for non-uniform surfaces and basic shapes [2][3][4][5]. The innovative nano-finishing procedure MAF uses magnetic field-controlled and assisted cutting force control to remove very small asperities from magnetic or nonmagnetic materials, resulting in a nanometer-scale finish [6][7][8][9]. ...
CNC Magnetic Abrasive Finishing (CNC MAF) is famous for aluminium sheet processing. This study used an artificial neural network (ANN) analytical model with a Bayesian regularisation algorithm (BR) to examine how machine parameters (rotation speed, feed rate, depth of cut, and several passes) affect surface roughness during CNC MAF of aluminium sheet. Experimental and quantitative data proved its prediction ability. ANN model to select the best machine parameters for low surface roughness. The perfect numerical solution was experimentally tested, and surface morphology and roughness were used to evaluate processing quality under optimal machine parameters. The ANN model is also compared to Taguchi L16 for prediction and optimisation. Compared to ANN, prediction and optimal surface finishing mean absolute error are 96% lower. The results show that the ANN model is better at studying machine configuration during CNC MAF of Al sheet. SEM and 3D Optical profilometer were also used to analyze the Al sheet. The UV-VIS Spectrophotometer measures Al polished sample reflectance at 200–700 nm.
... This abrasive laden ballshaped MR fluid changes its compliance according to the surface to be polished and the gentle finishing can be achieved by changing the stiffness of the ball. This process has shown its capability to polish a wide range of materials like metallic, non-metallic, magnetic, and non-magnetic materials and all types of surfaces (2D and 3D) [7][8][9][10][11]. BEMRF produces scratch-free surfaces of nanometer-order surface roughness by controlling the finishing forces [12]. ...
Surface finishing of aluminium is a challenging task due to its soft nature and achieving nano level surface finish on aluminium surface is a daunting task even for the most advanced of the finishing processes. The material removal demands precise control of forces from these processes. Ball end magnetorheological finishing (BEMRF) process is one such process that can deliver precisely controlled forces and that too at confined and localized spaces. However, as aluminium is non-magnetic in nature it does not allow formation of an opposite magnetic pole for the process and hence the applied forces are low. To overcome this, a permanent magnet opposite pole is introduced beneath the sample surface which facilitates better forces and magnetic flux between the work surface and the tool tip. This research study is on the optimization of polishing fluid composition for the finishing of aluminium using BEMRF process. With the optimum fluid composition, the surface roughness of the aluminium sample is brought from 95.7 nm down to 53.6 nm in 32 minutes of finishing. The topographical analysis shows that the light scratches are completely removed from the surface and the deep scratches have turned into light discontinuous scratches after finishing. The finished surface is also free from the embedment of abrasive particles.
... This 3D-printed parts microstructure and surface roughness are impacted by the substantial temperature gradient caused by the fast cooling rates [20]. The surface roughness is typically high after the fabrication of any solid geometry, so post-finishing processes like shot peening [21], vibratory finishing/machining [22], magnetorheological finishing [23], laser polishing [24], chemical polishing, electrochemical machining [25][26][27][28], etc., are required to lower the surface roughness [20,21]. Different finishing techniques can be utilized depending on how complicated the component is, and these techniques are then used for real-world aerospace and wear-resistant applications. ...
In past years, machining processes have been required when fabricating the complex Inconel 718 parts, and these processes cause undesired tensile residual stresses. Inconel 718 also exhibits extreme work hardening throughout the machining process. To avoid these issues, recently, Inconel 718 parts with high geometric complexity and dimensional accuracy, the laser powder bed fusion (LPBF) process, which belongs to additive manufacturing, has been extensively used. These Inconel 718 parts with LPBF processing are frequently utilized in various industries, including aerospace, automotive, pharmaceutical, and food processing, because of their high strength, biocompatibility, and corrosion resistance. Wear resistance is essential in addition to these properties for designing and crushing applications. In this paper, tribological tests were conducted on the LBPF-processed Inconel 718 parts and compared to casted Inconel 718 parts against the four types of counter bodies, namely boron carbide, silicon carbide, tungsten carbide, and titanium carbide. The studies were carried out for 30 min with a constant load of 5 N, frequency of 10 Hz, and stroke length of 1 mm. In comparison to casted samples, LBPF-processed samples showed low COF values. The highest COF was observed on the cast Inconel 718 against the tungsten carbide counter body. The wear mechanisms were studied using SEM.
... Barzegar et al. (2022) used centrifugal disk finishing to investigate the surface and subsurface integrity of FDM parts, while Chand et al. studied the dimensional accuracy and mechanical characteristics of nut and bolt manufacturing using a multi-jet-based 3D printer. Valerga Puerta et al. (2020), experimented with corundum blasting to improve the surface finishing of FDM printed PLA components, while Kumar et al. (2019), studied the ball end magnetorheological finishing technique and was used to improve the surface quality of PLA parts printed with FDM. Dixit et al. provided a comprehensive review of different AFM variants that can be used to improve the surface finishing of different AM parts (Dixit et al., 2021). ...
Purpose
Three-dimensional (3D) printed parts usually have poor surface quality due to layer manufacturing’s “stair casing/stair-stepping”. So post-processing is typically needed to enhance its capabilities to be used in closed tolerance applications. This study aims to examine abrasive flow finishing for 3D printed polylactic acid (PLA) parts.
Design/methodology/approach
A new eco-friendly abrasive flow machining media (EFAFM) was developed, using paper pulp as a base material, waste vegetable oil as a liquid synthesizer and natural additives such as glycine to finish 3D printed parts. Characterization of the media was conducted through thermogravimetric analysis and Fourier transform infrared spectroscopy. PLA crescent prism parts were produced via fused deposition modelling (FDM) and finished using AFM, with experiments designed using central composite design (CCD). The impact of process parameters, including media viscosity, extrusion pressure, layer thickness and finishing time, on percentage improvement in surface roughness (%ΔRa) and material removal rate were analysed. Artificial neural network (ANN) and improved grey wolf optimizer (IGWO) were used for data modelling and optimization, respectively.
Findings
The abrasive media developed was effective for finishing FDM printed parts using AFM, with SEM images and 3D surface profile showing a significant improvement in surface topography. Optimal solutions were obtained using the ANN-IGWO approach. EFAFM was found to be a promising method for improving finishing quality on FDM 3D printed parts.
Research limitations/implications
The present study is focused on finishing FDM printed crescent prism parts using AFM. Future research may be done on more complex shapes and could explore the impact of different materials, such as thermoplastics and composites for different applications. Also, implication of other techniques, such as chemical vapour smoothing, mechanical polishing may be explored.
Practical implications
In the biomedical field, the use of 3D printing has revolutionized the way in which medical devices, implants and prosthetics are designed and manufactured. The biodegradable and biocompatible properties of PLA make it an ideal material for use in biomedical applications, such as the fabrication of surgical guides, dental models and tissue engineering scaffolds. The ability to finish PLA 3D printed parts using AFM can improve their biocompatibility, making them more suitable for use in the human body. The improved surface quality of 3D printed parts can also facilitate their sterilization, which is critical in the biomedical field.
Social implications
The use of eco-friendly abrasive flow finishing for 3D printed parts can have a positive impact on the environment by reducing waste and promoting sustainable manufacturing practices. Additionally, it can improve the quality and functionality of 3D printed products, leading to better performance and longer lifespans. This can have broader economic and societal benefits.
Originality/value
This AFM media constituents are paper pulp, waste vegetable oil, silicon carbide as abrasive and the mixture of “Aloe Barbadensis Mill” – “Cyamopsis Tetragonoloba” powder and glycine. This media was then used to finish 3D printed PLA crescent prism parts. The study also used an IGWO to optimize experimental data that had been modelled using an ANN.
... 8 But unfortunately, the poor surface quality and strength because of layer-by-layer addition of raster has limited its application in these areas. 9 The raster path tends to create peaks and valleys on the outer surface which results in surface roughness. 10 These printing lines also distorts the aesthetics of the fabricated parts. ...
The poor strength and surface texture of the additively manufactured components has restricted its usage as a functional part. The post processing methods can overcome this limitation and open new opportunities in different application areas. In the present study, chemical finishing process has been employed for the flexible components build through material extrusion based additive manufacturing technology. Thermoplastic polyurethane (TPU) has been chosen as the material for printing flexible parts. Taguchi orthogonal array‐based design of experiments has been employed. Three process parameters that is, solvent type, infill density and immersion time have been selected for the study. The percentage improvement in the surface roughness as physical property and compressive strength as mechanical property has been chosen as the response parameters. The dimensional deviation was investigated by measuring the change in the dimensions of the manufactured components. It has been observed from ANOVA analysis that the improvement in surface roughness and compressive strength depends significantly on the immersion time. The Dimethyl sulfoxide (DMSO) solvent and immersion time of 125 s has been found significant for different properties of the chemically treated TPU parts.
... The improvement of the performance of precision equipment is often accompanied by the improvement of the surface precision, surface finish, and structural complexity of parts [73]. The current research of MRF tools was based on the shape of the workpiece and improving the polishing efficiency as much as possible. ...
Precision complex surfaces components are in high demand for optical imaging, high-power lasers, and medical implants. Magnetorheological finishing (MRF) is widely used in ultra-precision machining of complex surfaces components due to its advantages of low processing cost, high precision, stable removal function, no surface damage, and the ability to achieve nano-scale surface roughness and micro-scale surface shape accuracy. However, the removal efficiency of MRF is still low, the material removal mechanism is not completely clear, and the properties of magnetorheological fluid (MR fluid) need to be improved, so its application in industrial production is limited. In order to further promote the development of MRF and break through the difficulties of current MRF, it is necessary to review and summarize the MRF technology. Recent studies progress on MRF need to be more comprehensive. It is not comprehensive to introduce only several different removal theories and the appearance of compound MRF. Research progress like MR fluid, MRF tools or other also should be mentioned in a short sentence. This paper gives a detailed literature review on MRF for complex surfaces. Firstly, the principle of MRF is introduced. The finishing tools are classified based on shape and the workpieces suitable for each tool are analyzed. Some new compound MRF techniques with high machining efficiency are introduced. Then, the researches on MRF influence function and force were reviewed, and the researches on three factors affecting MRF machining performance, including process parameters, MR fluid, and magnetic pole arrangement, were reviewed. Finally, the key works of MRF technology in the future are prospected: material removal theory, preparation of high performance MR fluid, and development of novel composite MRF based on interdisciplinary and universal optimization of MRF machine tools. This paper has important reference value for researchers in MRF-related fields.
... The uneven surface due to partially melted powders during the SLM process was finished, and the surface roughness was improved from Ra of around 7 μm to less than Ra 1 μm [80]. The schematic of rotatingvibrating magnetic abrasive polishing for the finishing of the AM parts is shown in Figure 5 120 Post-processing Techniques for Additive Manufacture and secondary [81]. Zhang et al. (2018) have used a magnetic-based finishing (MAF) method to finish additively manufactured (SLM) 316L stainless steel parts. ...
... Recently, a non-conventional method which is ball end magnetorheological finishing (BEMRF) process has been used for the nano-finishing of the FFF printed parts. Kumar et al. combined primary finishing process i.e., facing using lathe machine and secondary finishing process BEMRF to achieve the nano level surface finish of polylactic acid (PLA) parts [14]. Taufik et al. developed empirical models for measuring surface roughness of the laser treated parts manufactured by fused deposition modelling (FDM) process. ...
Fused filament fabrication (FFF) is the fast-growing additive manufacturing (AM) technology that enables the fabrication of complex 3D models using polymers at low cost. However, the inferior surface quality and high layer resolution of the build parts has limited its real-life application. Chemical treatment process is one of the low costs and highly effective post processing method which can be used for eliminating this disadvantage. It improves the surface finish of FFF build parts by dissolving the layers of the surface exposed to the chemical environment. The present research work investigated the effect of chemical treatment on the compressive strength, surface roughness and dimensional accuracy of the FFF printed flexible parts fabricated with thermoplastic polyurethane (TPU) filament. Two chemicals dimethyl formamide (DMF) and dimethyl sulfoxide (DMSO) have been used for the chemical treatment process. It has been observed that samples treated with DMSO exhibited better compressive strength and surface quality in comparison to DMF. A case study has been done to implement the outcome of the present investigation in real-life application.
... In this manner, the finishing is performed on the surface, as shown in Figure 6. Kumar et al. [19] studied this process and investigated the effect of the concentration of abrasive particles (APs) and electrolytic iron particles (EIPs) in the MR fluid. It was found that a higher concentration of EIP particles led to better boding of the MR fluid and more effective finishing. ...
... The effect of process parameters in the BEMRF process[19]. FDM-ed sample: (a) unfinished surface and (b) finished surface after applying the BEMRF process[19]. ...
... The effect of process parameters in the BEMRF process[19]. FDM-ed sample: (a) unfinished surface and (b) finished surface after applying the BEMRF process[19]. ...
The traditional manufacturing industry has been revolutionized with the introduction of additive manufacturing which is based on layer-by-layer manufacturing. Due to these tool-free techniques, complex shape manufacturing becomes much more convenient in comparison to traditional machining. However, additive manufacturing comes with its inherent process characteristics of high surface roughness, which in turn effect fatigue strength as well as residual stresses. Therefore, in this paper, common post-processing techniques for additive manufactured (AM) parts were examined. The main objective was to analyze the finishing processes in terms of their ability to finish complicated surfaces and their performance were expressed as average surface roughness (Sa and Ra). The techniques were divided according to the materials they applied to and the material removal mechanism. It was found that chemical finishing significantly reduces surface roughness and can be used to finish parts with complicated geometry. Laser finishing, on the other hand, cannot be used to finish intricate internal surfaces. Among the mechanical abrasion methods, abrasive flow finishing shows optimum results in terms of its ability to finish complicated freeform cavities with improved accuracy for both polymer and metal parts. However, it was found that, in general, most mechanical abrasion processes lack the ability to finish complex parts. Moreover, although most of post-processing methods are conducted using single finishing processes, AM parts can be finished with hybrid successive processes to reap the benefits of different post-processing techniques and overcome the limitation of individual process.
