Impact of Rheology-Based Optimum Parameters on Enhancing the Mechanical Properties and Fatigue of Additively Manufactured Acrylonitrile–Butadiene–Styrene/Graphene Nanoplatelet Composites
Abstract
:1. Introduction
2. Experiments
2.1. Materials and Specimen
2.2. Thermal Analysis
2.3. Rheological Properties
2.4. Tensile and Fatigue Tests
3. Results and Discussion
4. Conclusions
- The shark-skin effect, closely linked to the material’s rheological behaviour, emerged as a significant factor adversely impacting static strength and fatigue life. Optimising the temperature of all four heating zones of the extruder for filament production and utilising higher nozzle temperature (270 °C) for 3D-printed samples were proposed to address this challenge.
- The addition of 1.0 wt.% GNPs to the ABS matrix and a modification made to the temperature of the extruder’s heating zones significantly enhanced the elastic modulus and UTS of the nanocomposite filaments. In particular, the proposed parameter optimisation led to filaments with minimised shark-skin effects and an 8% higher UTS and 34% higher elastic modulus compared to pure ABS.
- The 3D-printed samples produced with a higher nozzle temperature exhibited increased fatigue lives at all raster orientations compared to those manufactured under identical conditions as pure ABS.
- The research underscores the critical importance of optimising parameters such as temperature range, the extruder’s rotational speed, and printer nozzle temperature to achieve ideal sample quality. Achieving a delicate balance between viscosity levels is vital in ensuring high-quality 3D-printed samples with smooth surfaces.
Author Contributions
Funding
Institutional Review Board Statement
Data Availability Statement
Conflicts of Interest
References
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Layer height (mm) | 0.2 |
Printing speed (mm/sec) | 20 |
Infill density (%) | 100 |
Nozzle diameter (mm) | 0.4 |
Nozzle temperature (°C) | 250, 270 |
Bed temperature (°C) | 110 |
Filament Type | Temperatures (°C) | RPM | Surface Condition | |||
---|---|---|---|---|---|---|
Zone 1 | Zone 2 | Zone 3 | Zone 4 | |||
Filament 1 (pure ABS) | 220 | 230 | 230 | 240 | 3.5 | Excellent |
Filament 2 (containing 1.0 wt.% GNPs) | 220 | 230 | 230 | 240 | 3.5 | Excessive shark skin |
Filament 3 (containing 1.0 wt.% GNPs) | 220 | 230 | 230 | 240 | 5.5 | Less shark skin |
Filament 4 (containing 1.0 wt.% GNPs) | 247 | 250 | 250 | 260 | 5.5 | Good |
Filament Type | UTS (MPa), SD | Young’s Modulus (MPa) |
---|---|---|
Filament 1 (pure ABS) | 36.9, 2.1 | 1642 |
Filament 3 (containing 1.0 wt.% GNPs) | 37.8, 1.2 | 2095 |
Filament 4 (containing 1.0 wt.% GNPs) | 39.9, 2.4 | 2203 |
3D-Printed Samples | 0° Raster Angle | 45° Raster Angle | 90° Raster Angle | ||||||
---|---|---|---|---|---|---|---|---|---|
UTS (MPa) | E (MPa) | Strain (%) | UTS (MPa) | E (MPa) | Strain (%) | UTS (MPa) | E (MPa) | Strain (%) | |
Fabricated with Filament 1 | 32.4 | 1522 | 5.6 | 32.9 | 1591 | 5.9 | 29 | 1489 | 3.9 |
Fabricated with Filament 3 | 34.4 | 1556 | 5.5 | 34.2 | 1702 | 4.8 | 29.8 | 1549 | 4.1 |
Fabricated with Filament 4 | 35.5 | 1772 | 3.8 | 34 | 1733 | 4.4 | 30 | 1639 | 2.7 |
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Hassanifard, S.; Behdinan, K. Impact of Rheology-Based Optimum Parameters on Enhancing the Mechanical Properties and Fatigue of Additively Manufactured Acrylonitrile–Butadiene–Styrene/Graphene Nanoplatelet Composites. Polymers 2024, 16, 1273. https://doi.org/10.3390/polym16091273
Hassanifard S, Behdinan K. Impact of Rheology-Based Optimum Parameters on Enhancing the Mechanical Properties and Fatigue of Additively Manufactured Acrylonitrile–Butadiene–Styrene/Graphene Nanoplatelet Composites. Polymers. 2024; 16(9):1273. https://doi.org/10.3390/polym16091273
Chicago/Turabian StyleHassanifard, Soran, and Kamran Behdinan. 2024. "Impact of Rheology-Based Optimum Parameters on Enhancing the Mechanical Properties and Fatigue of Additively Manufactured Acrylonitrile–Butadiene–Styrene/Graphene Nanoplatelet Composites" Polymers 16, no. 9: 1273. https://doi.org/10.3390/polym16091273