Integration of fuzzy logic with response surface methodology for predicting the effect of process parameters on build time and model material volume in fdm process

Abstract

Fused Deposition Modelling (FDM) is a promising additive manufacturing (AM) technique used for various prototyping requirements where relatively cheap yet robust models are required. To improve FDM process effectiveness, appropriate process parameters selection is required for high productivity and cost effectiveness. Build time (BT) and volume of Model material (MMV) required are important responses to measure cost effectiveness. In this work, response surface methodology (RSM) and fuzzy logic (FL) have been applied to reduce the build time and model material volume for experimentation. The process parameters namely contour width, air gap; raster angle and spatial orientation are considered. Also, build time and model material volume has been taken as responses for this study. Thirty experiments were conducted on Acrylobutadiene Styrene (ABS) P400 for conical primitives using full factorial central composite RSM design. The optimum process parameter conditions were obtained from FL. The results obtained provide useful information of the method to control responses and ensure minimal build time and model material volume for prototyping requirements. The assessment outcome provided a scientific reference to obtain minimal values of build time and model material volume utilized, and it was found out that these correspond to a contour width of 0.654 mm, air gap of 0.0254 mm, raster angle of 0° and orientation (rotation about x-axis keeping z height minimum) of 30°.