Statistical and Empirical Modeling

of
Shrinkage in parts fabricated by
FFM Process

under supervision of

Dr. Vineet Srivastava & Mr. Gurpreet Singh

Saini

Copyright 2013-2014

A Research Plan Presentation

By
Shekhar Saini
801481022
ME - CCR

Product Development

Joining

Forming
Layer Deposition or Rapid
Prototyping

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Machining

What is Rapid prototyping?

Rapid Prototyping (RP) refers

to
new
class
of
manufacturing
machines
which
quickly
produce
physical prototypes from
3D CAD models.

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A prototype is defined as An approximation of a

product or system or its components in some form for
a definite purpose in its implementation.

pplications of RP

Design
CAD model
Verification
Visualizing Object
Proof of concept
Engineering Analysis
and Planning
Form and Fit model
Stress Distribution
Diagnostic and
Surgical Operation
Planning
Surgical
Preplanning

WASHING MACHINE ROTOR

CONNECTING ROD OF ENGINE

HOUSING FOR DRILLING

MACHINE

HIGH SPEED VENTILATION

SYSTEM

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roblem Areas of RP
Accuracy
Strength
Surface roughness
Part deposition orientation
Build time
Support structure
Form Factor

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otivation

Accuracy of tessellation from the CAD model

Slicing algorithm
Powder
granulometry
(in
Powder
based
systems)
Beam offset (in Laser mounted system)
Shrinkage

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RP prototypes should have high accuracy in order

to ensure proper functional requirements. The
accuracy of an RP process is difficult to predict as
it is a function of many factors

Shrinkage does not occur in a uniform manner. The

shrinkage of a new layer can be constrained by the
existing part substrate. In addition, areas at high
temperatures tend to shrink more than those at lower
temperatures and part geometries such as thick walls or
sections can increase the shrinkage.

To compensate for shrinkage, a material shrinkage

coefficient is calculated and a scaling factor is applied in
each direction to the STL file

The resulting geometry can be slightly oversized compared

with the nominal geometry, depending on the scaling
factor used. Therefore, the present work aims on finding
out the effect of process parameters on shrinkage for
better accuracy. Statistical models of shrinkage along X, Y
and Z-axes will be developed to scale up the STL file for

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hrinkage

Literature Review

Wang
et al.
(1996)

Acrylic
based
polymer,
SL
(Stereo
lithography).

Cross-Sectional Profile of multi-layer structure

Derive
relationship
between
post
curing shrinkage
and
process
parameters(post
curing duration,
laser
power,
layer pitch)

Using
least
square
method
relationship
between post curing
shrinkage and process
parameters
were
derived.

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Rapid prototype manufacturing using the

Stereolithography technique

Dao
et ABS
plastic, To
Improve
al.
FDM
(Fused dimensional
(1999)
Deposition
accuracy.
Modeling)

It was found that an SCF of

1.010 will produce a 53%
reduction in mean error of
the dimensions.

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Christmas tree

Xiangwei
Wang (1999)

Polystyrene
in
powder
state,
Selective
laser
sintering(SLS).

Scaling factor k and beam offset b/2 with

part weight

To derive basic
formula
for
shrinkage
and
beam offset.

For
good
accuracy
different parts
should
be
applied
different beam
offset
depending
on
weight of the
part
as
shrinkage is not

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Beam offset and shrinkage calibration

procedure

Choosing
the
machine, laser
and
resin
parameters

Determination
of
curing
curves
in
different
directions

Drawing of new
solid part

Saving
the
drawn
model with a format
which is recognizable
by PE software

Assembly
of
the solid and
liquid parts

Drawing
the
liquid
parts
using
Boolean
Operations

Importing the
assembly
in
the PE software

Determination
of
the
mechanical
properties

R.
Nosouhi
and
S.
Rahmati
(2010)

Acrylic based
photopolymer
, SL (Stereo
lithography).

Obtaining
results

To
reduce
shrinkage by FE
Analysis and Star
weave
hatching
method.

the

Parts
produced
using
Circular
Star
weave
hatching
method
are
more accurate than those
produced by Star weave.

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Methodology

Assembly of solid and liquid

parts, applying the loads
and boundary conditions,
meshing, etc.

D.
Karalekas
and
A.
Aggelopoul
os (2002)

Acrylic
based
photopolymer,
SL
(Stereo
lithography).

To
calculate
magnitude of
the
resulting
shrinkage
strains.

Specimens post-cured
under intense UV light
exhibited
a
uniform
shrinkage
while
thermal
post
curing
results
in
higher
shrinkage.

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Schematic representation of experimental

Schematic diagram of two-layer resin laminate
setup for measuring out-of-plane
before and after deformation.
deflections.

Wang et Polystyrene
in
al.
powder
state,
(2006)
Selective
laser
sintering(SLS)

Minimize
the
shrinkage using
neural
network
to
define
relationship
between process
parameters and
shrinkage.

By lowering scanning
speed, higher laser
power and highest
allowable
temperature
of
working environment
improves accuracy.

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Trained result of the training sets using different numbers of hidden

neurons

Research Gaps
From literature survey it has been observed that
maximum work regarding part strength is
concerned on FDM, SLS, SL technologies.

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It has been observed that there is no work related

to parts related to 3D printing technology in
relation to the accuracy of the parts developed.

Research Objective
Based on the literature survey presented, following
objectives are being proposed.
To Develop a Statistical model based on the
effect of various process parameters on
shrinkage of parts fabricated by FFM method.

To Develop an empirical relationship between

process parameters and shrinkage.

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To Validate the developed model and optimize

the shrinkage.

Research Objective
To fulfill these objectives the process parameters
selected for fabrication are as follows:
Medium
level

High level

Nozzle
diameter
(mm)

0.2

0.3

0.4

Layer
Thickness
(mm)

0.1

0.2

0.3

Part bed
Temperatur
e ( c)

108

110

112

10

30

50

Length of
part
(mm)

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Low
level

1. Solid modelling of specimen according to standards.

2. Selection of process parameters and there ranges
based on the machine limitations.
3. Creation of design of experiment plans to establish
testing conditions.
4. Fabrication of specimen based on test condition.
5. Experimental testing to generate data for statistical
modelling(based on doe plan).
6. Estimation of error and validation of statistical models.
7. Optimization of responses based on the limitation of the
process parameters.
8. Empirical Modeling of shrinkage.
9. Thesis writing.

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Methodology

Work plan
201415

2015-16

2015-16

II Sem

I Sem

II Sem

Literature survey.
To prepare CAD model of parts in CAD package.
To prepare design of experiment (DOE) according
to process parameters
To fabricate the parts according to DOE plans.

Validation and optimization of process parameters

for mechanical properties.
Empirical Modeling of shrinkage.
Thesis writing.

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To study the effect of process parameters on preselected mechanical properties.

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Parts to be fabricated

1. W. L. Wang, C. M. Cheah, J. Y. H. Fuh and L. Lu. Influence of

process parameters on stereolithography part shrinkage,
Materials & Design. Vol. 17, No. 4, pp. 205-213, 1996.
2. Quang Dao, Jane C. Frimodig, Hung N. Le, Xiao Zhe Li and Boris
Fritz. Calculation of Shrinkage Compensation Factors for Rapid
Prototyping (FDM 1650), Computer Applications in Engineering
Education. vol. 7, no. 3, pp. 186-195, 1999.
3. Xiangwei Wang, "Calibration of shrinkage and beam offset in
SLS process", Rapid Prototyping Journal, Vol. 5, Iss 3, 1999.
4. R. Nosouhi and S. Rahmati, Finite Element Analysis of
Shrinkage Phenomena in Stereolithography and Development
of a New Hatching Method, 10th Iranian Conference on
Manufacturing Engineering, ICME 2010.
5. D. Karalekas and A. Aggelopoulos, Study of shrinkage strains
in a stereolithography cured acrylic photopolymer resin,
Journal of Materials Processing Technology, 136, 146150, 2003.

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References

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6. Rong-Ji Wang, Lingling Wang, Lihua Zhao and Zijian Liu,

Influence of process parameters on part shrinkage in SLS,
Int J Adv Manuf Technol, 33, 498504, 2007.
7. Lecture Slides by Dr. Vineet Srivastava, Introduction to RP,
dated on 12/01/2015.
8. Lecture Slides by Dr. Vineet Srivastava, Principle, Steps,
Process Chain of RP, dated on 12/01/2015.
9. Lecture Slides by Dr. Vineet Srivastava, Classification of
RP, dated on 19/01/2015.

Copyright 2013-2014

Thank You