Research On Cost And Tolerance Of Fused Deposition Modeling Staircase Effect

In recent years,3D printing has attracted more and more attention due to its own unique advantages.And fused deposition modeling(FDM)technology is the most widely used among various 3D printing technologies due to its environmental protection,low cost,and simple operation.And quickly became popular in various manufacturing fields.However,because the FDM technology uses the principle of layer-by-layer stacking,there are obvious staircase effects in the workpieces.The staircase effect not only reduces the accuracy and surface quality of the workpiece,but also reduces customer satisfaction,which seriously affects the application and development of fused deposition modeling technology.For the staircase effect problem of FDM workpieces,it is mainly because the accuracy of the fused deposition modeling workpiece with the staircase effect cannot meet the tolerance requirements;and the precision of the workpiece can meet the tolerance requirements,the production cost and the quality control cost is so high that customers are reluctant to purchase.In a word,The problem of the staircase effect is the contradiction between cost and tolerance of FDM workpiece.This study takes the cost and tolerance of the FDM staircase effect as the research object.First the study introduces Taguchi's quality management concept,and uses the quality loss function as the theoretical basis to deal with the contradiction between the cost and tolerance of staircase effect.Then,the article,based on the FDM technology principle and manufacturing process,and the causes of the staircase effect,model the zero-degree and non-zero-degree staircase effect with the process parameters.Next,the staircase effect of the FDM part is taken as the characteristic value and measured by the roughness.The parameter design of the zero-degree and non-zero-degree staircase effects is respectively carried out,finding out the main process parameters affecting the non-zero degree staircase effect are the printing direction and the layer thickness and proving the validity of non-zero-degree staircase effect process parameter model.For the zero-degree staircase effect,it was found that the layer thickness,the wire output rate,the feed speed and the nozzle temperature all have an influence on the staircase effect through the parameter design,and the best process parameter combination of the zero-degree staircase effect robustness are layer thickness of 0.08 mm,threading rate of 100%,feed rate of 30mm/s,nozzle temperature of 190?.The nozzle temperature has a certain effect on the zero-degree staircase effect,and the nozzle temperature is not considered in the zero-staircase effect model,so the influence of the nozzle temperature on the staircase effect cannot be ignored.Therefore,the main effect of the zero-degree staircase effect is obtained through the response surface design experiment The process parameters are the layer thickness and the wire-out rate,and it is predicted that the process parameter combination when the zero-degree staircase effect is minimum are: layer thickness of 0.08 mm,wire-out rate of 97%,feed rate of 30mm/s,nozzle temperature of 190?.Then through experiments,it is verified that the mean and variance are less than the optimal combination of robustness.Finally,analysing the cost and tolerance of the FDM with the actual situation,the quality loss function models of the zero-degree and non-zero-degree staircase effects are established respectively.When the layer thickness of 0.08 mm,threading rate of 100%,feed rate of 30mm/s and the nozzle temperature is 192?,taking the thread-out rate and layer thickness as adjustment parameters,the quality loss cost of the staircase effect is minimized and the adjustment method in effect.