Mathematical and Statistical Analysis of Fused Filament Fabrication Parameters for Thermoplastic Polyurethane Parts via Response Surface Methodology

Wajdi Rajhi, Ali B. M. Ali, Dheyaa J. Jasim, Omid Mehrabi (), Lotfi Ben Said and Mahmoud Moradi ()
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Wajdi Rajhi: Department of Mechanical Engineering, College of Engineering, University of Ha’il, Ha’il City 81451, Saudi Arabia
Ali B. M. Ali: Air Conditioning Engineering Department, College of Engineering, University of Warith Al-Anbiyaa, Karbala 56001, Iraq
Dheyaa J. Jasim: Department of Petroleum Engineering, Al-Amarah University College, Maysan 62001, Iraq
Omid Mehrabi: Department of Mechanical Engineering, Esfarayen University of Technology, Esfarayen 96619-98195, Iran
Lotfi Ben Said: Department of Mechanical Engineering, College of Engineering, University of Ha’il, Ha’il City 81451, Saudi Arabia
Mahmoud Moradi: Faculty of Arts, Science and Technology, University of Northampton, Northampton NN1 5PH, UK

Mathematics, 2024, vol. 12, issue 19, 1-19

Abstract: This work aims to analyze the effects of the main process parameters of fused filament fabrication (FFF) on the mechanical properties and part weight of 3D-printed thermoplastic polyurethane (TPU). Raster angle (RA), infill percentage (IP), and extruder temperature (FFF) in the ranges of 0–90°, 15–55%, and 220–260 °C, respectively, were considered as the FFF input parameters, and output variables part weight (PW), elongation at break (E), maximum failure load (MFL), ratio of the maximum failure load to part weight (Ratio), and build time (BT) were considered as responses. The Response Surface Methodology (RSM) and Design of Experiments (DOE) were applied in the analysis. Subsequently, the RSM approach was performed through multi-response optimizations with the help of Design-Expert software. The experimental results indicated a higher maximum failure load is achieved with an increased raster angle and decreased extruder temperature. ANOVA results show that ET has the most significant effect on elongation at break, with elongation at break decreasing as ET increases. The raster angle does not significantly affect the part weight of the TPU samples. The ratio of the maximum failure load to part weight of samples decreases with an increase in IP and ET. The results also indicated that the part weight and build time of FFF-printed TPU samples increase with an increase in IP. An ET of 220 °C, RA of 0°, and IP of 15% are the optimal combination of input variables for achieving the minimal part weight; minimal build time; and maximum elongation at break, maximum failure load, and ratio of the maximum failure load to part weight.

Keywords: additive manufacturing; fused deposition modeling; thermoplastic polyurethane; mechanical properties; design of experiments; response surface method (search for similar items in EconPapers)
JEL-codes: C (search for similar items in EconPapers)
Date: 2024
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