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Mechanical Behaviour of Carbon Fibre Reinforced PLA (CFRP)
Manufactured Using Fused Deposition Modelling Technique
Sharvesh M. Joshi*¹, Shreyash S. Patil1, Sanket B. Kinekar1, Karan A. Shah1,
P. P. Mangave2
1
Student, 2Lecturer
Department of Mechanical Engineering, Sharad Institute of Technology, Polytechnic, Yadrav,
(Ichalkarnji), Maharashtra, India
ABSTRACT developed by FDM process [1-2]. The analysis
Rapid prototyping (RP) technology is creating of different parameters utilised during
a physical model in layer by layer manner component printing aids in improving the quality
immediately from their CAD without the use of the intended parts for the analysis of process
of any tool, Dies and Fixture. Rapid parameters. Various methods of organisation are
prototyping, in Comparison to traditional available [3-4]. Taguchi’s approach is one of the
processes, can readily and quickly build greatest testing method is available for reducing
complicated parts, also reduces time & number of jobs manufactured out of all the
overall product development cost. Early procedures accessible. By literature survey, the
detection and mitigation of design errors are process parameter infill percentage is not used in
aides by RP. The percentage of infill material previous work and lack of work on CFRP is
Layer Thickness and specimen orientation found therefore, the aim of the paper is to study
were all modified in this investigation. The the effect of process parameters like Infill
thickness of the layers was varied between percentage, orientation angle and layer thickness
0.1mm, 0.2mm and 0.3mm about the by using FDM (Pramaan Mini) on CFRP [5-6].
horizontal plane, the orientation parameters From this study we can determine the effect of
were changed to 00, 450, 900. A total of 9 trials different variations like layer thickness,
were chosen for testing using Taguchi's orientation in angle, infill percentage and air gap
Design of Experimental Method for L9 [7]. Experiments were carried out.
orthogonal array of three parameters with
three distinct levels from 27 experiments. The Using Taguchi's design of trials, each
best tensile strength was obtained for a main variation has three sub variations. The
specimen with CFRP material of 0.2mm layer layer thickness and infill percentage determine
thickness, 60% infill, 00 orientation. surface quality and accuracy of manufactured
job. Orientation of angle has little sometimes.
Keywords-- 3 Dimensional printing, Carbon The air gap has a negative impact on
Fibre Reinforced PLA, FDM process dimensional accuracy and has a little impact on
surface quality. B. H. Lee et al evaluated process
factors to obtain optimum elastic performance of
INTRODUCTION a compliant ABS prototype for greatest throwing
distance [8-9]. They discovered the primary
In all of the RP manufacturing methods process parameters that affect the prototype’s
fused deposition modelling (FDM) is commonly performance as a result of this. Experiments
utilised in the industrial sector to fabricate were carried out to confirm the effectiveness of
complicated component quickly. In Fig. 1, this approach. The Taguchi method, a powerful
process of RP using fused deposition modelling tool to design optimization for quality was used
is shown. The Quality of parts manufactured by to find the optimal process [10-11]. Due to the
using FDM process depends on various open-source release of the RepRap (self-
parameters. Thus, it is important to study process Replicating Rapid prototype) 3D printing on a
parameters for attending desired quality modest scale has seen a significant increase in
parameters which is required in the parts popularity. Rapid Fused filament fabrication
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(FFF) (material extrusion according to ASTM Youmagine, Libre3D, NIH 3D Print Exchange)
Standard F2792-12a) is utilised in 3D printers, have been releasing thousands of designs,
and various Rapid printer designs account for the resulting in an exponential rise of open-source
bulk of 3D printers in use today [12]. At-home 3D printing designs that is projected to continue.
3D printing allows for decentralised This trend is being sat the consumer level since
manufacturing in both developing and developed 3D printers have been shown to be a cost-
countries. Previous research has demonstrated effective purchase for the middle class in
such production not only lowers cost of items for industrialised countries and the maker
customers but has a lesser environmental impact. community.
Users from various 3D printing repositories (e.g.
Figure 1: Process of Rapid Prototyping Using Fused Deposition Modelling.
LITERATURE REVIEW implant was demonstrated. The inner and
exterior surfaces of the prosthesis were
1. Gibson et al (2006) cited several examples created to fit the bone surface exactly based
of RP and related technology being on CT data. SLA was used for the
successfully used in medical applications. production of the physical model. The
In these research, it was discussed how implants and skull models were used in the
technology could be used to solve medical surgical planning. The SLA implant that
difficulties. RP has been found to help with results is used to make a mould, which is
a wide range of medical issues. They also then utilised to cast the Titanium item.
discussed some of the technology's limits 3. Additive Manufacturing (AM) or 3D-
and how to enhance it in the future. printing is the process of creating objects by
2. Singare et al (2005) tried to establish a successively depositing layers of material
computer assisted pre-fabricated implant based on 3D digital models. In additive
design and manufacturing method to manufacturing, Fused Deposition
improve the aesthetic outcome in chin Modelling (FDM) technology and ABS
surgery, according to the study's findings. (Acrylonitrile Butadiene Styrene) material
The use of medical RP technologies to are commonly employed. The mechanical
produce a personalised chin augmentation qualities of AM parts can't be specified or
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even approximated before they're built and deposition modelling printing. Layer by
tested, at least not yet. In this paper, a novel layer, the material is spread out until the
way to understanding how printing product is finished printing. Polylactic Acid
parameters influence the mechanical (PLA) and Acrylonitrile butadiene styrene
characteristics of printed parts is described, (ABS) these are most common two types
with the goal of determining how filament used in FDM printing. Various
components might be created (printed) to properties that can change the strength of
attain better mechanical properties. 3D printed piece are things such as infill
4. The approach is based on an experimental percentage, layer height, print orientation,
technique that can be used to determine the extruding temperature, and build speed to
best combination of manufacturing factors name a few. The mechanical strength of the
and their values in order to obtain the print was determined by testing the infill
desired result. The Taguchi methodology percentage and print orientation. The infill
was used as an optimization tool for percentage ranged from 20% to 100%, with
enhancing the mechanical properties of the increments of 20%. The purpose of this
part. project was to investigate the mechanical
5. The RepRap, an open-source self- strength of PLA when printed in different
replicating rapid prototype, has recently orientations and infill percentages.
made 3-D polymer-based printers 7. During uniaxial compression tests, the
affordable to the general public (for under paper gives experimental data on the effects
$500). As a result of the widespread use of of model placement and orientation on
3-D printing technology, mass-scale chosen mechanical parameters such as
distributed digital manufacturing is now Young's modulus and stress relaxation. The
possible. Currently, RepRap variants Dimension 1200es machine was used to
produce items primarily from acrylonitrile create cylindrical samples using fused
butadiene styrene (ABS) and polylactic acid deposition modelling techniques (FDM).
(PLA), which have melting temperatures On the machine platform, the samples were
low enough for melt extrusion outside of a positioned at various angles to the printing
specialised facility but high enough for direction. The ABS P430 material was
prints to hold their shape at average use utilised to make the samples. The ISO
temperatures. The mechanical properties of 3384: 2002 standard was used to conduct
RepRap printed items must be known in the relaxation tests. The tests were carried
order for them to be useful in engineering out on the Inspect Mini testing machine.
applications. The basic tensile strength and 8. Using variable open source 3D printers to
elastic modulus of printed components are 3D print functional items with known
measured in this study under realistic mechanical qualities is difficult. This
environmental circumstances for regular research looks at the mechanical properties
users of a variety of opensource 3-D of 3D printed items made from a variety of
printers. The average tensile strengths for materials using a commercial open-source
ABS and PLA are 28.5 MPa and 56.6 MPa, 3D printer. The samples are examined for
respectively, with average elastic moduli of tensile strength according to ASTM D638.
1807 MPa for ABS and 3368 MPa for PLA. The results and conclusions on the
Parts manufactured on tuned, low-cost, mechanical properties of several fused
open-source RepRap 3-D printers can be filament production materials are given.
considered as mechanically functional in The study demonstrates that the tensile
tensile applications as those from strength of a 3D printed specimen depends
commercial manufacturers, based on these largely on the mass of the specimen, for all
findings. materials. As a result, a two-step procedure
6. Printers that use fused deposition modelling is provided to address the difficulty of
(FDM) are becoming more common in uncertain print quality on mechanical
everyday life. Rapid prototyping is made characteristics of a 3D printed part, with a
much easier with these types of 3D printers. reasonable expectation that The tensile
The printing material is melted and strengths of a part will be discussed in this
extruded through a nozzle in fused study for a certain material. First, the print's
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exterior is visually evaluated for sub- dimensional accuracy, and manufacturing
optimal layers. The mass of the sample is time are among the response factors.
next measured to see if there has been any Taguchi's L9 orthogonal array is employed
under-extrusion in the interior. Using for the number of experimental runs. The
densities for the material and the volume of S/N ratio of Taguchi was utilised to find a
the object, this mass is compared to the set of process parameters that produce good
theoretical value. This two-step approach results for specific response characteristics.
enables low-cost open source 3D printers to Analysis of variance is used to determine
increase their object creation capabilities to the effectiveness of each parameter. Nylon
include functional parts. is the material used in the process
9. In the last several years, additive parameter studies. Analysis of variance is
manufacturing (AM) technologies have used to determine the effectiveness of each
advanced to the point that many of them parameter. Nylon is the material employed
can now produce functioning parts rather in the process parameter studies.
than just prototypes. AM has a lot of 11. 3D printing has replaced the complete
advantages, notably in terms of design production firm/system with its superior
freedom. However, because to the lack of version of constructing parts layer by layer
detailed design standards for AM, it employing additive approach and new
currently lacks industrial relevance. trends in the field of emerging technology.
Although AM is frequently promoted as a A detailed analysis was conducted in this
solution to all traditional production design article to compare it against traditional
constraints, the reality is that AM merely manufacturing methods for the creation of
replaces existing constraints with a new set components and complicated products for
of constraints. To fully benefit from the hundreds of diverse applications. 3D
advantages of AM, it is crucial to recognise printing is a versatile and quick process that
and evaluate these limits early in the design accelerates innovation while reducing
phase. The creation of design energy use, minimising material waste, and
considerations in AM allows for the compressing supply chains. This paper also
optimization of parts and processes. The describes the feed mechanism and process
design factors discussed in this paper will related information, supporting material,
lead to improved part quality. Because of its software used in 3D printer.
common use and availability, the work 12. Rapid prototyping (RP) refers to a set of
focuses on Fused Deposition Modelling procedures that may swiftly construct any
(FDM). The authors conducted experiments three-dimensional item into a model or
on the effect of elevated service prototype, directly from a CAD file
temperature on the performance of FDM developed by adding individual cross-
PLA parts, benchmarking the ability of sectional layers to the part. RP has
FDM to print overhangs and bridges progressed from prototyping for form, fit,
without supports, studying the effect of and function testing to producing finished
processing parameters on dimensional end products for functional use over the
accuracy, and the effect of processing years. FDM, a RP technique has made its
parameters on the modulus of elasticity of mark for providing cost effective product
final FDM samples. The work includes a along with making impossible geometries
case study that looks into the proper possible. It also validates performance prior
clearances for FDM parts, as well as a to implementation. Fused deposition
redesign for AM case study of a support Modelling is being used to shorten and
bracket that was previously created using simplify the product development cycle
traditional methods, taking into account the cost efficiently and many applications,
design concerns highlighted in this paper. including as aerospace, medical, vehicle,
10. The process parameters for fused deposition and consumer products, benefit from this
modelling (FDM) are discussed in this technology. This paper focuses on the
paper. The process factors studied are layer Fused Deposition Modelling (FDM)
thickness, orientation angle, and shell technique, as well as the use of FDM in
thickness. Ultimate tensile strength, aerospace applications, with a case study of
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Aeronautics Engineering using FDM as the product cycle time (courtesy of Stratasys
only cost-effective approach to reduce and DRDO).
DESIGN OF EXPERIMENTS
Figure 2: Dimensions of Tensile test specimen using D638 ASTM.
For testing of tensile strength of the TAGUCHI METHOD
CFRP material ASTM D638 is the most
common method for best results with respect to All 27 jobs are transformed to 9-
the tensile properties. In this method the specimens utilising L9 orthogonal array
specimen having shape of Dum bell or dog according to Taguchi's method for specimen
bone, as shown in Fig. 2. The specimen is put reduction, and the findings shown by these 9
through its paces on a universal testing machine. specimens are the same as the 27 specimens
All specimens should be examined when using according to this Taguchi method study. Table 1
the ASTM standard. shows the design of experiments using
Taguchi’s L9 orthogonal array.
Table 1: Design of Experiments (DOE) using Taguchi's L9 Orthogonal Array.
TENSILE TESTING SETUP is 0.5-500 mm/min, and the clearance between
the upper and lower columns is 450 mm/min.
Polymer Universal Tensile Testing is This machine operates at 230V with a 50Hz
used to test the tensile strength of our job. This frequency. We kept our specimen inside the
Polymer UTM is made by FIE Group and is a specimen calm and applied a tear rate of
completely automatic machine with the model 1mm/min. Fig. 3 shows the setup used for tensile
designation UNITEC 9450. With a load range of testing.
0 to 50 KN, the crosshead speed on this machine
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Figure 3: Tensile Testing setup.
UTM RESULTS of high tensile stress. The ensuing shapes at the
Behaviour of Material against Tensile Testing end of the fractured fragments following a
failure give this style of fracture its name.
Cup and cone fractures are a form of Fractured objects may be more susceptible to
failure that occurs when ductile metals and corrosive environments. Fig. 4 shows the CFRP
polymers are subjected to a uniaxial strain. It is specimen before testing and Fig. 5 shows the
the splitting of a body into two pieces as a result CFRP specimen after testing.
Figure 4: CFRP Specimen before testing.
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Figure 5: CFRP Specimen after testing.
Ultimate Tensile Stress
Table 2: Ultimate Tensile stress.
JOB UTS (MPa) MAX. LOAD (N)
G1 1.924 39.950
G2 2.160 50.600
G3 2.291 63.900
G4 2.160 62.275
G5 2.333 55.250
G6 3.169 67.350
G7 2.189 52.525
G8 2.585 57.825
G9 2.730 66.850
A total 9 jobs have been experimentally 67.350 Newton load acted then we got 3.169
tested to determine the ultimate tensile stress. UTS in MPa. For job G7 52.525 Newton load
Table 2 shows Max. Load sustained by the acted then we got 2.189 UTS in MPa. For
specimen and their Ultimate Tensile Strength 57.825 Newton load acted then we got 32.585
(UTS) for job G1 39.950 Newton load acted then UTS in MPa. For job G9 66.850 Newton load
we got 1.924 UTS in MPa. For job G2 50.600 acted then we got 2.730 UTS in MPa. From
Newton load acted then we got 2.160 UTS in which specimen the G6 specimen shows best
MPa. For job G3 63.900 Newton load then we results with its Layer Thickness 0.2mm Infill
got 2.291 UTS in MPa. For job G4 62.725 Percentage 60% and 00 orientation. Because it
Newton load then we got 2.160 UTS in MPa. has more number of layer which causes more
tensile force to break the specimen while testing
For job G5 55.250 Newton load acted as compared to other specimen.
then we got 2.333 UTS in MPa. For job G6
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Comparison of PLA and CFRP
Figure 6: Variations of Load Vs Displacement for PLA Material.
Figure 7: Variations of Load Vs Displacement for CFRP Material.
In Fig. 6, variations of Load Vs was 766.5 Newton load & UTS was observed to
Displacement for PLA material is shown. In be 36.5 MPa. The maximum load sustained by
PLA a total 9 jobs have been experimentally job G7 was 838.25 Newton & UTS was
tested to determine the ultimate tensile stress. observed to be 39.91 MPa. The maximum load
The maximum load sustained by job G1 was sustained by job G8 was 715.75 Newton & UTS
567.5 l Newton & UTS was observed to be was observed to be 34.04 MPa. The maximum
27.02 MPa. The maximum load sustained by job load sustained by job G9 was 751.25 Newton &
G2 was 826.75 Newton & UTS was observed to UTS was observed to be 35.77 UTS in MPa.
be then 39.36 MPa. The maximum load
sustained by job G3 was 937.25 Newton & UTS In PLA Specimen G3 shows the best
was observed to be l 44.63 MPa. The maximum Results With its Layer Thickness 0.1mm, Infill
load sustained by job G4 was 785.25 Newton & Percentage 60% and perpendicular orientation
UTS was observed to be 37.39 MPa. The The G3 specimen shows best results because it
maximum load sustained by job G5 was 920.25 has more number of layer which causes more
Newton load & UTS was observed to be 43.82 tensile force to break the specimen while testing
MPa. The maximum load sustained by job G6 as compared to other specimen.
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In Fig. 7, variations of Load vs average surface roughness value of the 3D
Displacement for CFRP material are shown. In printer for CFRP material is 5.2903 micro meter.
CFRP, a total 9 jobs have been experimentally
tested to determine the ultimate tensile stress. CFRP is composite material of Carbon
The maximum load sustained by job G1 was fibre reinforced and PLA. CFRP decomposed in
39.950 Newton & UTS was observed to be nature. Due to easily of recycling of this material
1.924 MPa. The maximum load sustained by job its application is wide. CFRP have high strength
G2 was 50.600 Newton & UTS was observed to and light in weight & it has great dimensional
be then 2.160 MPa. The maximum load accuracy. CFRP is also best option for replacing
sustained by job G3 was 63.900 Newton & UTS metallic materials. Due to its high resistance but
was observed to be 2.291 MPa. The maximum light in weight it best suitable for aerospace and
load sustained by job G4 was 62.725 Newton & automotive engineering.
UTS was observed to be 2.610 MPa. The
maximum load sustained by job G5 was 55.25 FUTURE SCOPE
Newton load & UTS was observed to be 2.333
MPa. The maximum load sustained by job G6 Analysis of various 3D printing materials
was 67.350 Newton load & UTS was observed like ABS Filament, Peek Filament, nylon
to be 3.169 MPa. The maximum load sustained Filament, and many more.
by job G7 was 52.525 Newton & UTS was Variations in testing like Fatigue Testing,
observed to be 2.189 MPa. The maximum load Compression Testing, 3 Point bending test
sustained by job G8 was 57.825 Newton & UTS and many more tests can be performed
was observed to be 2.585 MPa. The maximum using these materials for future study.
load sustained by job G9 was 66.850 Newton & By varying the temperature of the printing
UTS was observed to be 2.730 UTS in MPa. bed and change the temperature of
atmosphere the test can be performed on the
In CFRP the G6 specimen shows best material.
results with its Layer Thickness 0.2mm, Infill Variation of the parameters of the printing
Percentage 60% and 00 orientation. Because it technique can be possible for the testing of
has more number of layer which causes more the material like changing the pattern of
tensile force to break the specimen while testing deposition, decreasing the gap between the
as compared to other specimen. layer thickness of the printing.
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