Evaluation of the influence of build and print orientations of unmanned aerial vehicle parts fabricated using fused deposition modeling process

Abstract The principal objective of this study is to provide an insight into the simulation of fused deposition modeling (FDM) parts considering the influence of build and print orientations. The elastic modulus, strength and Poisson's ratio at different build and print orientations are obtained by performing uniaxial tensile tests. Based on the results, an appropriate material model is formed and validated by conducting flexural tests on a flat and curved layer FDM (CLFDM) parts fabricated in various print and build orientations. It is found that the influence of the print orientation or different raster angle is minimal and an averaged isotropic material model can be used to simulate parts in a particular build orientation. The build orientation influences the elastic mechanical response of the flat and CLFDM parts largely. A case study on a flying wing unmanned aerial vehicle (FW-UAV) is presented to analyze the contribution of the build orientation on the strength of the structure. The case study shows that the effect of build orientation in some instances might not be critical and a thorough understanding of the loads interacting with the part is necessary before analyzing the building parameters.

[1]  S. Ebeid,et al.  Mechanical behaviour of ABS: An experimental study using FDM and injection moulding techniques , 2016 .

[2]  Selçuk Güçeri,et al.  Mechanical characterization of parts fabricated using fused deposition modeling , 2003 .

[3]  Ranjan Ganguli,et al.  Multidisciplinary Design Optimization of an UAV wing using Kriging based Multi-Objective Genetic Algorithm , 2009 .

[4]  Han Tong Loh,et al.  Considerations and selection of optimal orientation for different rapid prototyping systems , 1999 .

[5]  Neil Hopkinson,et al.  Effect of section thickness and build orientation on tensile properties and material characteristics of laser sintered nylon‐12 parts , 2011 .

[6]  Sarat Singamneni,et al.  Raster angle mechanics in fused deposition modelling , 2015 .

[7]  Ismail Durgun,et al.  Experimental investigation of FDM process for improvement of mechanical properties and production cost , 2014 .

[8]  Todd Letcher,et al.  Failure Analysis and Mechanical Characterization of 3D Printed ABS With Respect to Layer Thickness and Orientation , 2016, Journal of Failure Analysis and Prevention.

[9]  Bin Huang,et al.  Curved Layer Fused Deposition Modeling with Varying Raster Orientations , 2013 .

[10]  A. F. Silva,et al.  Fused deposition modeling with polypropylene , 2015 .

[11]  K. Leong,et al.  Investigation of the mechanical properties and porosity relationships in fused deposition modelling‐fabricated porous structures , 2006 .

[12]  Dimitri N. Mavris,et al.  A Framework for Integrated Analysis, Design, and Rapid Prototyping of Small Unmanned Airplanes , 2016 .

[13]  Gerald Kress,et al.  Investigation of local load introduction methods in aircraft pre-design , 2012 .

[14]  Cameron J. Turner,et al.  An implicit slicing method for additive manufacturing processes , 2018 .

[15]  Olaf Diegel,et al.  Modeling and evaluation of curved layer fused deposition , 2012 .

[16]  Gregory Taylor,et al.  Experimental investigation of effects of build parameters on flexural properties in fused deposition modelling parts , 2017 .

[17]  Ruzy Haryati Hambali,et al.  Effect of build orientation on FDM parts:a case study for validation of deformation behaviour by FEA , 2010 .

[18]  A. K. Sood,et al.  Parametric appraisal of mechanical property of fused deposition modelling processed parts , 2010 .

[19]  Turgay Kıvak,et al.  Optimization of surface roughness and flank wear using the Taguchi method in milling of Hadfield steel with PVD and CVD coated inserts , 2014 .

[20]  Ji Zhao,et al.  Influence of Layer Thickness and Raster Angle on the Mechanical Properties of 3D-Printed PEEK and a Comparative Mechanical Study between PEEK and ABS , 2015, Materials.

[21]  Jordi Llumà,et al.  Mechanical property characterization and simulation of fused deposition modeling Polycarbonate parts , 2015 .

[22]  Alokesh Pramanik,et al.  Evaluating Mechanical Properties and Failure Mechanisms of Fused Deposition Modeling Acrylonitrile Butadiene Styrene Parts , 2017 .

[23]  Yucel Orkut Aktas,et al.  Design of a Commercial Hybrid VTOL UAV System , 2013, 2013 International Conference on Unmanned Aircraft Systems (ICUAS).

[24]  W. C. Smith,et al.  Structural characteristics of fused deposition modeling polycarbonate material , 2013 .

[25]  Chun-Li Lin,et al.  Evaluation of contributions of orthodontic mini-screw design factors based on FE analysis and the Taguchi method. , 2010, Journal of biomechanics.

[26]  Xin Wang,et al.  An improved fused deposition modeling process for forming large-size thin-walled parts , 2016 .