Parametric Study on Vibration Analysis and Surface Roughness of Fused Deposition Modeling-Printed Parts under Multi-material Dampers for Additive Manufacturing Applications
摘要
In fused deposition modeling (FDM), the surface integrity and dimensional accuracy are significantly influenced by machine-induced vibrations, which are the result of dynamic interactions between the print head and the developing structure. In this work, a 5 × 5 × 5 cm3 cube was used to build and assess three FDM-compatible damper materials: rubber, thermoplastic polyurethane (TPU), and carbon fiber-reinforced polylactic acid (PLA–CF) under identical printing circumstances. A vibrometer was used to quantify vibration characteristics such as acceleration, velocity, frequency, and displacement, while a contact profilometer was used to evaluate surface roughness. The rubber damper had a surface roughness of 3.42 ± 0.21 µm and moderate vibration levels (acceleration ~ 0.50-0.53 m/s2 displacement ~ 2.0-3.0 × 10−1 m). PLA–CF achieved lower roughness (2.15 ± 0.17 µm) and decreased displacement (~ 2.0-2.5 × 10−1 m), but because of its increased stiffness, it was sensitive to acceleration spikes. TPU exhibited reduced acceleration (0.48-0.51 m/s2), controlled velocity (0.0023-0.0028 m/s) and increased displacement (3.0-4.0x10−2 m) that was mainly controlled by low frequency activity (45-55 Hz). In spite of the increasd displacement, TPU exhibited the maximum surface quality with Ra = 1.63 ± 0.11 µm and Rz = 20.4 µm. The results corroborate the notion that vibration frequency and acceleration are both critical factors in the development of faults. Overall, the TPU is the most efficient damper for additive manufacturing applications due to its ability to effectively suppress high-frequency disturbances, which results in exceptional surface integrity.