GRD Journals- Global Research and Development Journal for Engineering | Volume 4 | Issue 9 | August 2019 ISSN: 2455-5703
A Study on the Effect of Infill Percentage and Infill Pattern on the Compressive Behaviour of the FDM Printed Polylactic Acid (PLA) Polymer Anas Mirza Baig M. Tech student Department of Mechanical Engineering Integral University, Lucknow, U. P. (India) Dr. K. M. Moeed Associate Professor Department of Mechanical Engineering Integral University, Lucknow, U. P. (India)
Md. Shakibul Haque Sr. Lecturer Department of Mechanical Engineering Integral University, Lucknow, U. P. (India)
Abstract Fused deposition modelling (FDM) is chiefly using polylactic acid (PLA) as material of choice. PLA can be used to print a var iety of components like medical implants, domestic products & mechanical parts etc. The variation in infill pattern as well as infill percentage impacts the mechanical behaviour of the printed part. In the present study FDM printed PLA specimens subjected to compressive tests in order to observe their behaviour under compressive forc es. Keywords- Fused Deposition Modelling (FDM), Polylactic Acid (PLA), Infill Percentage, Infill Pattern, Compressive Strength
I. INTRODUCTION One of the biggest advantage of the 3D printing technology is that the components with different infill geometries and infill patterns can be printed. This not only saves material but also reduces the overall component cost. 3D printing process has been succes sfully utilized in comparative study of biostructure [12], scaffold structures [14], micro-fabrication [6] and light weight UAV (unmanned aerial vehicles) [11] and design of police whistles [13]. This process is also used for studying the compressive and tensile behaviour of Natural Sand Stone [8]. Many prior study has suggested that this process can be used to print a wide variety of polymers [15] and composites [7] even multi-nozzle extrusion printing is also possible [16], [4]. This process is also capable of printing density variables parts [17], with different type of infill generation [18]. Literature survey of prior investigation reveals that there is a significant effect of printing orientation, density, and filler pattern [19], layer thickness and raster angle [1], [20], [5] , [6] on mechanical performance of part like compressive performance [19], fatigue performance [21] , surface roughness tensile streng th [3], [9] and maximum flexure properties [2], [22]. The study has also shown that this process can also be integrated with design and manufacturing data [12].
II. WORK METHODOLOGY A. Test Specimens Test specimens were printed using FDM technology. The cross section of the specimen used was 12.7 mm Ă— 12.7 mm with a length of 25.4 mm. The specimens were printed with three different infill patterns i.e. hexagonal, triangular, and linear and three different infill percentages i.e. 25%, 50%, and 100%. The general values for the material properties are following: PROPERTY Bulk Density (g/cm3) Infill (%) Shell Thickness Layer Thickness Printing method Printer Printing firm Infill Pattern Colour Extruder temperature Bed Temperature
VALUE 1.24 g/cm3 25% , 50% , 100% 0.3 mm 0.3 mm FDM Flash Forge Guider II INTEGRAL UNIVERSITY Hexagonal, linear and triangular Red 220 o C 65 o C
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A Study on the Effect of Infill Percentage and Infill Pattern on the Compressive Behaviour of the FDM Printed Polylactic Acid (PLA) Polymer (GRDJE/ Volume 4 / Issue 9 / 002)
B. Printer Specifications Name Number of Extruder Print Technology Build Volume Layer Resolution Build Accuracy Positioning Accuracy
Guider Ⅱ 1 Fused Filament Fabrication(FFF) 280*250*300mm 0.05 - 0.4mm ±0.2mm Z axis 0.0025mm; XY axis 0.011mm
Filament Diameter
1.75mm （±0.07） 0.4mm 10~200 mm/s FlashPrint
Nozzle Diameter Print Speed Software
C. Universal Testing Machine The Universal Testing Machine used for performing co mpressive test was model UTE 40 manufactured by Fuel Instruments & Engineers Pvt. Ltd. (Mumbai, India). The specifications of the UTM are: Max. Capacity - 400 kN Measuring range - 0 – 400 kN Loading unit - Hydraulic Control panel - Electronic Extensometer – Electronic D. Compressive Test 3 specimens of each combination was tested and the mean value was taken for the conclusion purpose. The failure of the specimen was considered when either plastic deformation has reached or printing layer separation was observed. Procedure was as follows: Load the specimen on the UTM Start the machine Record the load and corresponding deflection Plot the curve using excel E.
Formula used Stress = Load applied / cross section area of the specimen Strain = Deformation / original length Strength to weight ratio = Strength / Mass of specimen Young’s Modulus = Stress/ Strain
III. RESULTS AND CONCLUSION A. Results After conducting several experiments the results obtained are gathered in tabular form below: Failure compressive load Hexagonal Triangular Linear
25% 5.6 4.58 5.26
50% 7.03 5.75 6.56
100% 6.61 6.61 6.61
All the values presented above are in Kilo-Newtons. To visualize the distribution of above data following graph is plotted:
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A Study on the Effect of Infill Percentage and Infill Pattern on the Compressive Behaviour of the FDM Printed Polylactic Acid (PLA) Polymer (GRDJE/ Volume 4 / Issue 9 / 002)
1) Strength to Weight Ratio Strength to weight ratio is an important consideration when speaking of infill percentages. The following data has been obser ved in the present experiment: Hexagonal Triangular Linear
25% 2.63 1.94 2.40
50% 2.13 1.65 1.96
100% 1.17 1.17 1.17
To visualize above data following graph has been generated:
2) Young’s Modulus The test data obtained is used to calculate the young’s modulus. The results have been shown below: Hexagonal Triangular Linear
25% 8.81 7.21 8.28
50% 11.07 9.05 10.33
100% 10.41 10.41 10.41
All the values presented above are in kN/mm2 When the above data is plotted following graph appeared:
B. Conclusions Maximum yield load of 7.03 kN was observed for Hexagonal pattern with 50% infill while the minimum 4.58 kN was for triangular with 25% infill Although solid specimen started to yield at lower load than hexagonal with 50% but after yield point due to solid infill the load required for further deformation kept increasing while in all other cases it kept decreasing The stress strain analysis suggested that all the infill percentage and infill patterns combination shows somewhat similar graph with exception solid infill condition Maximum Strength to weight ratio observed was 2.63 in hexagonal pattern with 25% infill while Minimum Strength to weight observed was 1.17 in case of 100% infill specimen The graph of infill vs printing time suggested that the maximum printing time occurred around 90% infill percentage for the given infill pattern, usually increasing infill percentage more than 50% yields more printing time than 100% infill this is d ue to complex movements that printer has to make in order to print the patterns inside the specimen
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A Study on the Effect of Infill Percentage and Infill Pattern on the Compressive Behaviour of the FDM Printed Polylactic Acid (PLA) Polymer (GRDJE/ Volume 4 / Issue 9 / 002)
The graph of infill percentage vs material used plots almost a straight line as expected logically, the maximum variation was observed in triangular infill pattern while the minimum variation is observed in linear infill pattern The maximum Young’s Modulus observed was 11.07 kN/mm2 in the case of Hexagonal pattern with 50% infill while the minimum Young’s Modulus observed was 7.21 kN/mm2 in the case of triangular infill pattern with 25% infill pattern
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