Mechanical Anisotropy Behavior of Fused Deposition Modelling Abs

(1)

(2)

PREFACE

NSPM 2009 is the formal proceedings of the 9th National Symposium on Polymeric Materials held in Residence Hotel Uniten Bangi on 14-16^th December 2009. It is also organised with The Plastics and Rubber Institute Malaysia PRIM. The symposium proceedings consist of 78 papers covering a large number of issues on experimental and analytical studies of polymeric materials.

The objectives of the symposium are to review the state-of-the art, present and latest findings and exchange ideas among engineers, researchers and practitioners involved in this field. We strongly hope the outcomes of this symposium will stimulate and enhanced the progress of experimental and analytical studies on polymeric materials as well as contribute to the fundamental understanding in the related field.

The papers were submitted with limited amount of possible editing. The policy of editing was the content of the material and its rapid dissemination was more important than its form. Even though misspelling and grammatical errors were corrected, there was no attempt to revise the materials to correct solecism.

We are grateful to all the authors for their papers and presentations in this symposium.

They are also the ones who help make this symposium possible through their hard work in the preparation of the manuscripts. We would also like to offer our sincere thanks to all the invited speakers who came to share their knowledge with us.

We would also like to acknowledge the untiring efforts of the editors, research assistants and students in meeting deadlines and for their patience and perseverance.

We are indeed honoured to associate this event with Department of Mechanical and Manufacturing, and Faculty of Engineering, Universiti Putra Malaysia.

Finally, we appreciate the sponsor support provided by Faculty of Engineering, The Plastics and Rubber Institute Malaysia, PRIM and PETRONAS.

Thank you all.

Aidy Ali, Chief Editor

(3)

EDITORIAL BOARD

Professor Ir. Dr. Mohd Sapuan Salit Dr. Aidy Ali

Dr. Mohd Khairol Anuar Mohd Ariffin Dr. Edi Syams Zainudin

Dr. B.T Hang Tuah Baharudin Dr. Faieza Abdul Aziz

Dr. Nuraini Abdul Aziz

Dr. Azmah Hanim Mohamed Ariff Riza Wirawan

Mohd Zuhri Mohamed Yusoff Mohamad Ridzwan Ishak Abdul Aziz Hairuddin Mohd Hafizul Ismail Mohamed Abd. Rahman Sairizal Misri

Nurhaniza Mohamad

(4)

1 5 9 10 15 69

AN OVERVIEW OF OIL PALM FIBRE - POLYMER COMPOSITES 69-77

M.Y.M. Zuhri, S.M. Sapuan and N. Ismail

DEVELOPMENT OF A GREEN COMBAT ARMOR 78-89

Z.R. Shaker, A. Aidy, and K. Abdan

EVALUATION OF NATURAL FIBRE COMPOSITES USING ANALYTICAL HIERARCHY PROCESS 90-95 A. Hambali, S.M. Sapuan, N. Ismail and Y.Nukman

SELECTION OF MATERIALS USING ANALYTICAL HIERARCHY PROCESS AND PUGH’S SELECTION METHOD 96-103 A. Hambali, S.M. Sapuan, N. Ismail and Y. Nukman

TENSILE PROPERTIES OF LOW DENSITY POLYETHYLENE (LDPE)/PALM KERNEL SHELL (PKS) BIOCOMPOSITES: THE EFFECT OF ACRYLIC ACID (AA).

103-113 A. Romisuhani, H. Salmah and H.Akmal

EFFECT OF MOISTURE ABSORPTION ON THE MECHANICAL PROPERTIES OF SOIL BURIED KENAF FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

114-123

A.A.A. Rashdi, S.M. Sapuan, M.M.H.M. Ahmad and A. Khalina

INFLUENCE OF WATER ABSORPTION IN MECHANICAL PROPERTIES OF NATURAL FIBRES FROM KENAF UNSATURATED POLYESTER COMPOSITES

124-132 A.A.A. Rashdi, S.M. Sapuan, M.M.H.M. Ahmad and A. Khalina

FULL PAPERS MESSAGES KEYNOTE SPEAKERS PROGRAM LAYOUT

CONFERENCE PROGRAM DETAILS ABSTRACTS

RADIATION PREVULCANIZED NATURAL RUBBER LATEX: CYTOTOXICITY AND SAFETY EVALUATION ON ANIMAL 133-138 C.K. Chai, W.M.W. Zin, P. Ibrahim and S. Ibrahim

DURABILITY SIMULATION OF ELASTOMERIC MATERIALS USING FINITE ELEMENT METHOD (FEM) 139-149 C. W. Chieh, Aidy Ali, A. B. Sanuddin, Reza Afshar

THE EFFECT OF ELECTRON BEAM IRRADIATION ON THE TENSILE PROPERTIES OF PINEAPPLE LEAF FIBRE (PALF) REINFORCED HIGH IMPACT POLYSTYRENE (HIPS) COMPOSITES

150-154 J. P. Siregar, S. M. Sapuan, M. Z. A. Rahman, H. M. D. K. Zaman

DEVELOPMENT OF COMPUTER CASING USING OIL PALM FIBRE REINFORCED EPOXY COMPOSITE 155-161 K. W. Ham, S.M. Sapuan, MYM Zuhri, B.T Hang Tuah Baharuddin

THE DEVELOPMENT OF POLYMER MATERIALS SELECTION SYSTEM USING PHPMYADMIN 162-171 N.K. Mun, A.M. Fairuz, A. Hambali, and S.M. Sapuan

FINITE ELEMENT ANALYSIS OF COMPOSITE MATERIALS FOR AEROSPACE APPLICATIONS 172-182 M. Nurhaniza, M.K.A. Ariffin, A. idy, F. Mustapha and A.W.Noraini

MODELING OF IONIC TRANSPORT IN SOLID POLYMER ELECTROLYTES 183-189

P. L. Cheang, L. L. Teo and T. L. Lim

(5)

TABLE OF CONTENTS

EFFECTS OF NATURAL WEATHERING ON PROPERTIES OF LINEAR DENSITY POLYETHYLENE (LDPE)/ THERMOPLASTIC SAGO STARCH (TPSS) - KENAF FIBRE COMPOSITE

190-197 R. Abdul Majid, H. Ismail and R. Mat Taib

EFFECTS OF SOIL BURIAL ON PROPERTIES OF LINEAR DENSITY POLYETHYLENE (LDPE)/ THERMOPLASTIC SAGO STARCH (TPSS) BLENDS

198-204 R. Abdul Majid, H. Ismail and R. Mat Taib

SYNTHESIS & PROPERTIES OF THERMOTROPIC LIQUID CRYSTALLINE POLYIMINES CONTAINING AROMATIC AND HETEROAROMATIC MOIETIES

205-212

R.Ratnamalar and A.M. Issam

CHEMICAL TREATMENTS AND TENSILE PROPERTIES OF SUGARCANE BAGASSE RIND FILLED POLY (VINYL CHLORIDE) 213-219 R. Wirawan, S.M. Sapuan, R. Yunus, A. Khalina

FLEXURAL PROPERTIES OF SUGARCANE BAGASSE PITH AND RIND REINFORCED POLY(VINYL CHLORIDE) 220-225 R. Wirawan, S.M. Sapuan, R. Yunus, K. Abdan

COMPARISON ON TENSILE PROPERTIES OF HYBRID AND NATURAL WOVEN SUGAR PALM FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

226-233

S. Misri, Z. Leman, S.M. Sapuan and M.R. Ishak

IMPACT STRENGTH OF HYBRID WOVEN SUGAR PALM FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES 234-237 S. Misri, Z. Leman, S.M. Sapuan and M.R. Ishak

METHOD SELECTION FOR FABRICATION OF SMALL BOAT APPLICATION OF NATURAL FIBRE COMPOSITES 238-242 S. Misri, Z. Leman, S.M. Sapuan and M.R. Ishak

EFFECT OF ANNEALING TEMPERATURE AND CONCENTRATION OF POLY[(9,9-DIOCTYLFLUORENYL-2,7-DIYL)-CO- (1,4–PHENYLENE)] ON PHOTOLUMINESCENCE INTENSITY OF POLYMER LIGHT EMITTING MATERIAL

243-248 S.N.S. Ridhuwan, H. Abu Hassa and Z. Hassan

TENSILE PROPERTIES, RUBBER-FILLER INTERACTION AND MORPHOLOGICAL OF KENAF FIBRE/HALLOYSITE 249-257 TENSILE PROPERTIES, RUBBER-FILLER INTERACTION AND MORPHOLOGICAL OF KENAF FIBRE/HALLOYSITE

NANOTUBES HYBRID FILLED NATURAL RUBBER COMPOUNDS

249-257 A.M. Norjulia, H.Ismail and Z.Ahmad

FRACTURE TOUGHNESS OF KENAF MAT REINFORCED POLYESTER MATRIX 258-269

Z.R. Shaker and A. Aidy

FABRICATION AND IMPACT PROPERTIES OF SHORT ABACA (MUSA TEXTILE NEE) FIBER-REINFORCED HIGH IMPACT POLYSTYRENE (HIPS) COMPOSITE

270-275 E.H. Agung, S.M. Sapuan, M.M. Hamdan, H.M.D. K. Zaman and U. Mustof

PALM OIL RADIATION CURABLE 1K BIO-POLYURETHANE FOR COATINGS APPLICATION 276-282 M.A. Faiza, R. Mohamed and M.M. Nagteni

COMPARISON OF EPOXIDISED NATURAL RUBBER (ENR) 37.5 AND ENR 25/ ENR 50 PHYSICAL BLEND: SPECIALTY POLYMER FOR ‘GREEN TYRE’ APPLICATION

283-288 N.Y. Wan, K.P. Chin and C.S. Mt Saad

FLOW BEHAVIOUR AND VISCOELASTICITY OF POLYPROPYLENE-KAOLIN COMPOSITES AT DIFFERENT TEMPERATURE 289-295 N.A.A. Rahim, Z.M. Ariff and A. Ariffin

(6)

EVALUATION OF SHAPE FACTOR FOR COMPONENTS WITH CURVED FREE AREA 296-304 N.A.M. Hassim

DEVELOPMENT OF BIODEGRADABLE PLASTIC COMPOSITE BLENDS BASED ON SAGO DERIVED STARCH AND NATURAL RUBBER

305-310

P.H. Yiu, B. Jaya-Raj, S.C. Kiing, H.H. Lee, S.C. Wong and A. Rajan

MORPHOLOGY AND MECHAINICAL PROPERTIES OF PLASTICIZED POLY (LACTIC ACID) 311-317 Z.A. Ali, R.M. Taib and Z.A.M. Ishak

EFFECT OF CITRONELLA GRASS FIBER ADDITION ON RICE STRAW-HIGH DENSITY POLYETHYLENE COMPOSITE 318-325 M.S. Abdul Ra'uuf , W.A.R. Wan Aizan

COMPARATIVE STUDY ON MOISTURE ABSORPTION OF KENAF BAST AND CORE FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

326-331 A.H. Abdullah, M.R. Ishak, K. Abdan, Z. Leman, and S.M. Sapuan

EFFECTS OF SILANE BASED COUPLING AGENT ON THE PROPERTIES OF KENAF CORE REINFORCED HIGH DENSITY POLYETHYLENE (HDPE)/SOYA POWDER COMPOSITES

332-343 A. Hamid Abdullah, H. Ismail and A. Abu Bakar

SYNTHESIS & LIQUID CRYSTALLINE PROPERTIES OF NEW TWIN DIGLYCIDYL ETHERS CONTAINING AZOMETHINE GROUPS

344-350

R.Ratnamalar and A.M. Issam

EFFECT OF POLYMER MICROSPHERE INCORPORATION ON IMPACT PERFORMANCE OF STF COTTON FABRIC COMPOSITE

351-357 S.M. Suhaimi, R. Mohamed, M.A. Faiza

CHITOSAN-STABILIZED NOBLE METAL NANOCATALYSTS AND THEIR EFFECTS ON THE HYDROGENATION OF PALM OIL WITHOUT ORGANIC SOLVENT

358-373 W. Lihua, S. Shafii, M.R. Nordin and K.Y. Liew

CORROSION PROTECTION OF CARBON STEEL USING POLYANILINE COMPOSITE WITH ALUMINUM OXIDE 374-384 A.A.D. Ahmed ,M.I. Khan and S. Hashim

SIMULATION: DC CHARACTERISTICS OF MOLECULAR ASSEMBLY SYSTEM 385-395

A. Boudjella and Brahim B. Samir

HYBRID COMPOSITES: STUDY ON UN-TREATED CELLULOSE FIBERS/GF PROPERTIES 396-402 A.M Ya’acob, A.A. Bakar, H. Ismail and K.Z. Dahlan

MONOMER CONCENTRATION EFFECT ON POLYAMINE SYNTHESIS AND ITS DEMULSIFYING ABILITY ON WATER IN OIL EMULSION

403-412 A.Ramdzan, N.A.S. Hami Nam and A.Ariffin

EFFECTS OF PROCESS PARAMETERS ON SELECTED PROPERTIES OF LIQUID COMPRESSION-MOLDED VINYL ESTER SHEETS

413-418

A.R. Mohamed, S.M. Sapuan, M. Shahjahan and A. Khalina

THE EFFECT OF PPMAH ON PROPERTIES OF POLYPROPYLENE (PP)/ RECYCLED ACRYLONITRILE BUTADIENE RUBBER (NBRR)/ RICE HUSK POWDER (RHP) COMPOSITES

419-425 S. Ragunathan, H. Ismail and K. Hussin

THE EFFECT OF AGEING ON ARENGA PINNATA FIBRE REINFORCED EPOXY COMPOSITE 426-435 S.E. Sinin, A. Aidy, A. B. Sanuddi

(7)

TABLE OF CONTENTS

EFFECTS OF DYNAMIC VULCANIZATION ON THERMAL PROPERTIES OF CALCIUM CARBONATE FILLED POLYPROPYLENE/ETHYLENE PROPYLENE DIENE TERPOLYMER COMPOSITES

436-444 S. Rohana, H. Salmah and H. Kamarudin

PREPARATION AND THERMAL BEHAVIOUR OF AN/EA COPOLYMER AND AN/EA/FN TERPOLYMER AS PRECURSORS FOR CARBON FIBER

445-452 S.N.A.M. Jamil, R. Daik and I. Ahmad

MECHANICAL ANISOTROPY BEHAVIOR OF FUSED DEPOSITION MODELLING ABS 453-461

S. Suraya , S.Sulaiman, S.H. Sheikh Md.Fadzullah, M. Sayuti, and M.K.A.Arifin1

THE EFFECTS OF CHEMICAL MODIFIERS ON THERMAL PROPERTIES OF CALCIUM CARBONATE FILLED POLYPROPYLENE/ETHYLENE PROPYLENE DIENE TERPOLYMER COMPOSITES

462-469

S. Rohana, H. Salmah and H. Kamarudin

MULTIWALL CARBON NANOTUBE FILLED NATURAL RUBBER:THE EFFECT OF FILLER LOADING AND MIXING METHOD 470-484 F.Ramly, H.Ismail, and N. Othman

REACTION OF EPOXIDIZED NATURAL RUBBER WITH NUCLEOPHILE COMPRISED AMINO AND HYDROXYL GROUPS 485-491 G. Raju and M.R.H. Mas Haris

A NEW STUDY ON MODIFIED DIPPING PROCESS OF NATURAL RUBBER LATEX FILMS: EFFECT OF CURING PARAMETERS ON TENSILE AND SWELLING PROPERTIES

492-499 H. Osman and N. Ismail

BEHAVIOR OF LOW DENSITY POLYETHYLENE (LDPE) TUBES UNDER QUASI-STATIC AXIAL AND DYNAMIC CRUSHING LOAD

500-514 H.H. Ya and H. El-Sobky

FIBRE/POLYETHYLENE REINFORCED COMPOSITES: A REVIEW 515-534

I.S. Aji, S.M. Sapuan, E.S. Zainudin, and A. Khalina

DEGRADABILITY AND SWELLING BEHAVIOR OF OIL PALM EMPTY FRUIT BUNCH-BASED SUPERABSORBENT POLYMER COMPOSITES

535-545

S. Jamaludin, and S. Hashim

SPECIFIC HEAT OF NEAT AND GLYCEROL PLASTICIZED POLYVINYL ALCOHOL 546-551

L. T. Sin, Wan Aizan W. A. R., Abdul Razak R., M. S. Nizam Salleh

VARIOUS MONOMER CONCENTRATIONS ON SYNTHESIS OF POLYDIALLYLDIMETHYLAMMONIUM CHLORIDE AND ITS APPLICATIONS AS FLOCCULANTS

552-564 M.A Razali, A.Ariffin, R. Ramly, N. Manis

ON THE VARIATION OF THE EXPERIMENTAL SHEAR MODULUS OF ELASTOMERS 565-571

M.I.S.A. Rahim and K. Ab. Malek

EXTRACTION, IDENTIFICATION AND ACETYLATION OF INULIN FROM DAHLIA TUBER (DAHLIA PINATA CAV.) 572-578 M. Hariono , M.F. Akbar, I. Sularsih, L. Najihah, S. Purwadi, A.W. Nugrahani

DEVELPOMENT OF COMBINATORIAL OPTIMISATION FOR CUTTING TOOL PATH STRATEGY 579-587 H.K.Alsultaney, M.K.A. Ariffin, B.T.H.T. Baharudin, A. Aidy F. Mustapha

THE TENSILE PROPERTIES OF SINGLE SUGAR PALM (ARENGA PINNATA) FIBRE 588-595

D. Bachtiar, S.M. Sapuan, E.S. Zainudin, A. Khalina, and K.Z.M. Dahlan

(8)

THERMAL PROPERTIES OF LOW DENSITY POLYETHYLENE/ALUMINA NANOCOMPOSITES 596-601 J.L.S. Ngu, A. Luqman Chuah, T.S.Y. Choong, C.T. Ratnam, A. Ibrahim, H. Mohamad

MECHANICAL PROPERTIES OF CHICKEN FEATHER FIBRE REINFORCED EPOXY COMPOSITES 602-611 F.B.H Nurul, A.H. Umar, S.M. Sapuan

VULCANIZATION AND COAGULANT DIPING OF EPOXIDISED NATURAL RUBBER LATEX 612-617 D. Darji and M.M. Said

POLYURETHANE/NATURAL FIBER COMPOSITES: A REVIEW 618-624

Y.A. El-Shekeil, E.S. Zainudin, and S.M. Sapuan

DEPROTEINIZED NR LATEX BY UREA TREATMENT USING FRESH FIELD LATEX 625-633

N.H. Yusof, M.M. Said, S. Kawahara

THERMOPLASTIC IMPACT PROPERTY IMPROVEMENT IN HYBRID NATURAL FIBER EPOXY COMPOSITE BUMPER BEAM

634-639 M.M. Davoodi, S.M. Sapuan, D. Ahmad, A. Aidy, A. Khalina

CONCEPTUAL DESIGN OF HYBRID BIO-COMPOSITE FOR AUTOMOTIVE BUMPER BEAM 640-646 M.M. Davoodi, S.M. Sapuan, D. Ahmad, A. Aidy, A. Khalina

DESIGN AND FABRICATION OF CHAIR FROM HYBRID BANANA PSEUDO-STEM/GLASS FIBRE REINFORCED POLYESTER COMPOSITE

647-654 M.I.H. Khamis, S.M. Sapuan, E.S Zainudin, R. Wirawan, B.T.H.T Baharuddin

SUGARCANE BAGASSE REINFORCED PVC: FROM WASTE TO GREEN COMPOSITES 655-660

R. Wirawan, S.M. Sapuan, R. Yunus, A. Khalina

MICROCELLULAR RUBBER: A STUDY ON RECLAIMED LATEX GLOVES (R-NRG) / SMR 20 BLENDS 661-667 P.C. Khaw, Y.W. Ngeow and C.S. Mt Saad

P.C. Khaw, Y.W. Ngeow and C.S. Mt Saad

EFFECTS OF MOISTURE CONTENT TO FLEXURAL PROPERTIES OF KENAF BAST FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

668-672

M.Y.M. Zuhri, M.R. Ishak, Z. Leman, S.M. Sapuan and A.M.M. Edeerozey

REVIEW ON PINEAPPLE LEAF FIBRE (PALF) – POLYMER COMPOSITES 673-678

M.Y.M. Zuhri, S.M. Sapuan and H.I.M. Hamdan

THE EFFECTS OF FIBRE CONTENT ON FLEXURAL AND IMPACT PROPERTIES OF WOVEN SUGAR PALM FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

679-686

M.R. Ishak, Z. Leman, S.M. Sapuan and S. Misri

THE EFFECTS OF SEA WATER TREATMENT ON TENSILE AND IMPACT PROPERTIES OF WOVEN SUGAR PALM FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

687-699

M.R. Ishak, Z. Leman, S.M. Sapuan and S. Misri

COMPARATIVE STUDY OF TENSILE PROPERTIES OF KENAF BAST AND CORE FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

700-708

M.R. Ishak, M.Y.M. Zuhri, S.M. Sapuan, Z. Leman, A.M.M. Edeerozey, I.S. Othman

THE DYNAMIC MECHANICAL ANALYSIS OF SUGAR PALM FIBRE REINFORCED HIGH IMPACT POLYSTYRENE (HIPS) COMPOSITES

709-716

D. Bachtiar , S.M. Sapuan , E.S. Zainudin , A. Khalina , and K.Z.M. Dahlan

FLEXURAL AND IMPACT PROPERTIES OF KENAF BAST AND CORE FIBRE REINFORCED UNSATURATED POLYESTER COMPOSITES

717-723

M.R. Ishak, R. Wirawan, S.M. Sapuan, Z. Leman, A.M.M. Edeerozey, I.S. Othman

(9)

Residence Hotel, Uniten, Putrajaya 14-16 December 2009

453

The 9^th National Symposium on Polymeric Materials 2009 (NSPM 2009)

MECHANICAL ANISOTROPY BEHAVIOR OF FUSED DEPOSITION MODELLING ABS

S. Suraya ^1*, S.Sulaiman¹, S.H. Sheikh Md.Fadzullah², M. Sayuti¹, and M.K.A.Arifin¹

1Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, 43400 Serdang, Selangor, Malaysia.

2Faculty of Mechanical Engineering, Universiti Teknikal Melaka Malaysia, 76109 Durian Tunggal, Melaka, Malaysia

*Email:sue_bahira@yahoo.com

ABSTRACT

This research is focus on one of rapid prototyping (RP) technologies that is Fused Deposition Modeling (FDM) using polymer-based material specifically Acrylonitrile-Butadiene-Styrene (ABS). RP technologies provide the ability to fabricate initial prototypes from various model materials. FDM is a typical RP process that can fabricate prototypes out of ABS plastic. To predict the mechanical behavior of FDM parts, it is important to understand the material properties of the raw FDM process material and the effect that FDM built parameter have on anisotropic material properties. Using the Design of Experiment (DOE) approach, the process parameter of FDM, build direction was examined. Mechanical anisotropy behaviors of the prototype were investigated via Tensile Test as per ASTM D638-01 and Compression Test as per ASTM D 695-96. Under tensile loading as per ASTM D638-01, it was found that the part produced in axial orientation (0ô) possessed the highest tensile strength of 23.81±0.24MPa followed by diagonal orientation (45ô) of 16.87±0.27MPa. Whilst the lowest value of tensile strength was observed for transverse orientation (90ô) with 11.21±0.05MPa.Under compressive loading as per ASTM D 695-96, the part produced in transverse orientation (90ô) possessed the highest compressive strength of 57.48±0.93MPa but lowest stiffness with 0.27±0.02GPa. The axial orientation (0ô) possessed the second highest compressive strength with 38.82±0.39MPa and highest stiffness of 0.93±0.01GPa and the lowest compressive strength is 24.40±2.21MPa at diagonal orientation (45ô) and the stiffness value is 0.81±0.08GPa. As a conclusion, mechanical anisotropy behavior is observed for parts produced from FDM machine as an effect of different build direction.

Keywords: Rapid Prototyping, ABS, Mechanical Anisotropy, Tensile Test

(10)

454

1. INTRODUCTION

Rapid prototyping is referred as a technology that can automatically construct physical models from Computer-Aided Design (CAD) database and produces a solid model (prototype) of the design in a short period of time depends on the size and complexity of the product [1, 2, 6, 7, 10, 11, and 12]. It is use in micro technologies, so the product is made very fast and the machine builds the parts in parallel [6, 7, 10, and 12]. In 1994, Pratt & Whitney achieved an order of magnitude (cost) reduction (and) time savings of 70 to 90 percent by incorporating rapid prototyping into their investment casting process. The process in the rapid prototyping is it takes virtual designs from CAD or animation modeling software and then the software packages will

“slice” the CAD model into a number of thin horizontal cross sections about 0.1mm layers, which are built up layer-by-layer until the model is finished. Figure 1 shows the basic process of rapid prototyping consists of the five steps.

Figure 1: The basic five-step process of rapid prototyping [10].

Fused Deposition Modeling (FDM) is a type of rapid prototyping commonly used within engineering design. FDM is a non-laser machine that produces three dimensional solid objects directly from CAD models[9]. FDM produces ABS plastic prototype models, which have high strength and durability.

In the Fused Deposition Modeling, (FDM) process is extruded in layers. A plastic filament or metal wire is melted and extruded through a heated nozzle. The nozzle moves to produce a profile of the part then moves down and the next layers is built on top until the entire prototype model is fully built [5, 8, 10, 12]. A flow diagram of the FDM process is shown in figure 2 [13].

Create a CAD model of the design Convert the CAD model to STL format

Clean and finish the model Construct the model one layer atop another Slice the STL file into thin cross-sectional layers

(11)

455

The common material used in FDM is acrylonitrile butadiene styrene (ABS), polycarbonates, (PC) (defining structures of thermoplastics), polyphenylsulfones (PPC) or Waxes.

Figure 2: FDM extrusion head[13].

In this research, the material will be use is P400 ABS. According to Rafiq, N. (2006), the advantage of ABS is that this material combines the strength and rigidity of the acrylonitrile and styrene polymers with the toughness of the polybutadiene rubber. ABS is a polymericed alloy of three materials acrylonitrile, butadiene and styrene. Acrylonitrile contributes with thermal and chemical resistance, butadiene gives ductility and impact strength and styrene gives the glossy surface and makes the material easily to machine and it also less expensive.The material is located under the group styrene plastic and it is one of most used plastics.

2. BUILD PARAMETER CONSIDERATION

According to Ahn, S.H. et al. (2002), find out how to predict the mechanical behavior of FDM parts. It is critical to understand the material properties of the raw FDM process material, and the effect that FDM build parameter have on anisotropic material properties. Using a design of experiment (DOE) approach, the process parameters of FDM such as raster orientation, air gap, bead width, color, and model temperature were examined.

In this research, it find the properties of ABS parts fabricated by the FDM 1650 and compare the result to the test specimen that fabricated by injection molding. For FDM parts made with a 0.03 inch overlap between roads, the typical tensile strength ranged from 65 and 72 percent of the

(12)

456

strength of injection molded ABS P400. The compressive strength ranged from 80 to 90 percent of injection molded FDM ABS.

The build parameter that affect the properties of FDM parts is a bead width is a bead width is the thickness of the bead (or road) that the FDM nozzle deposits. It can vary from 0.3mm (0.012inch) to 1mm (0.0396 inch) for the FDM 1650 machine. Air gap is the space between the beads of FDM material. The default is zero, meaning that the beads just touch. It can be modified to leave a positive gap, which means that the beads of material do not touch. The positive gap results in a loosely packed structure that builds rapidly. The air gap value can also be modified to leave a negative gap, meaning that two beads partially occupy the same space. This results in a dense structure, which requires a longer build time.

3. DESIGN OF EXPERIMENT

For Compression testing, the test specimens were made according to the ASTM D695-96, type 1.

ASTM D695 is the test method to determine the mechanical properties of unreinforced and reinforced rigid plastics, including the high-modulus composites, when loaded in compression at relatively low uniform rates of straining or loading. Test specimens of standard shape are employed [3]. The speed control at 1.3 mm/min (0.050 in./min) and start the machine

For Tensile testing, the test specimens were made according to the ASTM D638-01, type 1.

ASTM D638 is the test method will covers the determination of the tensile properties of unreinforced and reinforced plastics in the form of standard dumbbell-shaped test specimens when tested under defined conditions of pretreatment, temperature, humidity, and testing machine speed [4]. The speed control at 5 ± 25 % mm/min (0.2 ± 25 % in. /min) and start the machine

Parameters controlled in research is bead width, air gap, model build temperature, build direction and layer thickness Table 1 shows the level of setting for FDM machine.

(13)

457

Table 1: Level Setting [1].

Variable Level

Air Gap (inch. mm) 0.0/0.0

Road Width (inch. mm) 0.02/0.508

Model Temperature (^oC) 270

Orientation of Raster Axial, Diagonal, Transverse

Layer Thickness (mm) 0.178

Table 2 shows the number of specimens for each orientation. All parts design dimension and shape required are referring to ASTM standards. For tensile test refer ASTM D638-01 and for compression test refer ASTM D695-01.

The three layer orientations selected were 0ô, 45ô and 90ô relative to the x- axis. Five samples of each of the fifth teen trials were made for each orientation. Each trial was up accordingly and sent to the FDM machine via an SML file. Figure 3 also shows the two numbers indicate that layers alternate in their direction as the specimen is constructed.

Table 2: Number of specimens for each orientation.

Orientations Tensile test Compression test Number of specimens Number of specimens

Axial 5 5

Diagonal 5 5

Transverse 5 5

Total 15 15

Figure 3: Type of the build direction.

(14)

458

4. RESULTS AND DISCUSSION

The figure 4 shows the theoretical and experimental of modulus of elasticity, E of each orientation. The transverse orientation (90ô) specimen’s modulus of elasticity, E was 0.27±0.02GPa, which was the lower than the axial and diagonal orientation. The axial orientation (0ô) specimen’s modulus of elasticity, E was 0.97±0.01GPa which was higher than diagonal (45ô) orientation specimen’s, 0.81±0.08GPa. Among the three build direction, the transverse orientation process was most affected by built direction. These results explain that built direction caused the anisotropic behavior of parts produced via FDM machine; eventually their modulus of elasticity, E was changed by anisotropic behavior. The failure modes of the specimens at axial, diagonal and transverse build direction after compression testing are shown in figure 5.

Figure 4: Graph of modulus of elasticity versus orientations.

Figure 5: The failure modes of the specimens at axial, diagonal and transverse build direction after compression testing.

The figure 6 shows the theoretical and experimental of tensile strength, σ of each orientation.

The transverse orientation (90^o) specimen’s tensile strength, σ was 11.21±0.05 MPa, which was the lower than the axial and diagonal orientation. The axial orientation (0^o) specimen’s tensile

(15)

459

strength, σ was 23.81±0.24 MPa which was higher than diagonal (45^o) orientation specimen’s, 16.87±0.27 MPa. Among the three build direction, the transverse orientation process was most affected by built direction. These results explain that built direction caused the anisotropic behavior of parts produced via FDM machine. The comparison of the compressive strength, tensile strength and the modulus of elasticity are differing with different orientations. The result is σcompressive90o

> σcompressive0o

> σ compressive 45o

, E0o

> E45o

>E90o

, andσ_tensile0^o > σ tensile 45o

>σ tensile 90o

. The failure modes of the specimens at axial, diagonal and transverse build direction after tensile testing are shown in figure 7.

Figure 6: Graph of tensile strength versus orientation.

Figure 7: The failure modes of the specimens at axial, diagonal and transverse build direction after tensile testing.

5. CONCLUSION

Throughout this research, literature review was done to study of the Fused Deposition Modeling (FDM) process focusing on the processing parameters including build direction, layer thickness, bead width, air gap and model temperature in fabricate polymer part particularly the Acrylonitrile-Butadiene-Styrene (ABS). In this research, for different type of build direction (0ô, 45ô, 90ô), mechanical anisotropy behavior was observed when tested under tensile loading as per

(16)

460

ASTM D638-01 and compressive loading as per ASTM D 695-96. It was found that the part produced in axial orientation (0ô) possessed the highest tensile strength of 23.81±0.24MPa followed by diagonal orientation (45ô), 16.87±0.27MPa. Whilst the lowest value of tensile strength was observed for transverse orientation (90ô) with 11.21±0.05MPa.Under compressive loading as per ASTM D 695-96, the part produced in transverse orientation (90ô) possessed the highest compressive strength of 57.48±0.93MPa but lowest stiffness with 0.27±0.02GPa. The axial orientation (0ô) is the second highest compressive strength with 38.82±0.39MPa and highest stiffness with 0.93±0.01GPa and the lowest compressive strength is 24.40±2.21MPa at diagonal orientation (45ô) and the stiffness’ value is 0.81±0.08GPa. The material in axial orientation is a ductile while in diagonal orientation is a brittle material and at transverse orientation the material is ductile when under compressive loading and the material is brittle when under tensile loading. The best orientation to produce part from polymer-based via FDM machine is at 0ô orientation.

ACKNOWLEDGEMENT

The authors of this paper express their deep gratitude and sincere thanks to the staff and laboratory technicians of the Department of Mechanical Universiti Teknikal Malaysia Melaka for their help with the experiments

REFERENCES

[1] Ahn, S. H., Montero, M., Odell, D., Roundy, S. & Wright, P. K. (2002). “Anisotropic Material Properties of Fused Deposition Modeling ABS” Rapid Prototyping. 8. pp 248-257.

[2] Alexdenouden website, http://www.alexdenouden.nl/08/rapprod7.htm.

[3] ASTM (1996). “ASTM D695-96, Standard Test Method for Compressive Properties of Rigid Plastics.” United States :( D695-96).

[4] ASTM (1997). “ASTM D638-01, Standard Test Method for Tensile Properties of Plastics.”

United States :( D638-01).

[5] Bellehumeur, C., Li, L. M., Sun, Q. & Gu, P. H. (2004). “Modeling of Bond Formation between Polymer Filaments in the Fused Deposition Modeling Process” Manufacturing Process. pp1-4.

[6] Boejang, H., (2007). “An introduction to rapid prototyping” pp15-22.

[7] Cheshirehenburywebsite,http://www.cheshirehenbury.com/rapid/benefits.html.

(17)

461

[8] Lenau, T. (1996-2003). “Material ABS - acrylonitrile butadiene styrene”.

[9] Rafiq, N., (2006). “Rapid Prototyping Principles and Applications” 1th Ed. New Jersey:

John Wiley & Sons, Inc. pp1-5, 9, 19-20, 30-31, 34-49, 80-93, 156-167, 181-183, 310-317.

[10] Rodriguez, J. F., Thomas, J. P. & Renaud, J. E. (2003). “Design of Fused- Deposition ABS Components Stiffness and Strength” Mechanical Design. 125. pp 545-551.

[11] Wood, L. (1993). “Rapid Automated Prototyping: An Introduction, Industrial Press” New York.

[12] Zhong, W. H., Li, F., Zhang, Z., Song, L. & Li, Z. (2000). “Short Fiber Reinforced Composites for Fused Deposition Modeling” Materials Science and engineering. pp 1-5.

[13] Xpress3d website, http://www.express3d.com/fdm_process.

(18)