 For a long time, the issue with 3D printing was that it has demanded very

high entry costs, which does not allow profitable implementation to mass-
manufacturers when compared to standard processes. However, recent
market trends spotted have found that this is finally changing. As the market
for 3D printing has shown some of the quickest growth within.
Additive manufacturing's earliest applications have been on the tool room end
of the manufacturing spectrum. For example, rapid prototyping was one of the
earliest additive variants, and its mission was to reduce the lead time and cost
of developing prototypes of new parts and devices, which was earlier only
done with subtractive toolroom methods such as CNC milling and turning, and
precision grinding, far more accurate than 3d printing with accuracy down to
0.00005" and creating better quality parts faster, but sometimes too expensive
for low accuracy prototype parts. With technological advances in additive
manufacturing, however, and the dissemination of those advances into the
business world, additive methods are moving ever further into the production
end of manufacturing in creative and sometimes unexpected ways.
And in the decade of the century when we are more Focused on INDUSTRY
4.0 , 3D-printed material have become a revolutionary change
 MANUFACTURING
PROCESS

ADDITIVE
SUBTRACTIBE ZERO
MANUFACTURING
MANUFACTURING MANUFACTURING

ADDITIVE MANUFACTURING :It is yet another technological advancement made

possible by the transition from analog to digital processes
Additive manufacturing uses data computer-aided-design (CAD) software or 3D
object scanners to direct hardware to deposit material, layer upon layer, in
precise geometric shapes. As its name implies, additive manufacturing adds
material to create an object. By contrast, when you create an object by
traditional means, it is often necessary to remove material through milling,
machining, carving, shaping or other means.
Although the terms "3D printing" and "rapid prototyping" are casually used to
discuss additive manufacturing, each process is actually a subset of additive
manufacturing.
In all commercial RP process ,
the part is fabricated by
deposition of layer contoured
in a (X-Y) plane 2
dimensionally .The 3rd
dimension(Z) results from
single layers beling stacked
upon top of each other, But
not as a continuous Z Co-
ordinate .Therefore , the
prototypes are very exact on
the X-Y plane but have stair
stepping in Z direction .If
model is deposited with very
fine layers , i.e. smaller Z
stepping , model looks like
original.
GENERELISED DATA FLOW IN A COMMERCIAL RP PROCESS
DIFFERENT MEDIUM AND THEIR TYPES OF RAPID PROTOTYPING
 FUSED DEPOSITION MODELLING: FDM is primarily a rapid prototyping technique
that enables the quick, clean and cost efficient development of prototypes and
small functional components. It works through a CAD/CAM based design diagram,
which is fed to an FDM system. The system sends design-specific commands to a
controller head, which releases the melted thermoplastic accordingly. This
process is repeated layer by layer based on specific design coordinates. The
molten material becomes a solid object as soon it is exposed to a cooler
environment.
FDM 3D-PRINTER : (shown in the fig STRATASYS F170)
TRAY over which
material is been
made
MAIN MATERIAL
(ABS)

SUPPORT MATERIAL
(QSR)
 3D MODELING AND
SOFTWARE

I have used PTC’s CREO PARAMETRICS to model the work piece.

Though you can use any kind of modeling software e.g. SolidWorks,
SolidEdge , CATIA, AutoCAD 3D
 But Just we can not just feed in the Geometry that we have modelled in the
Modelling software , to run it properly it should be configured with the 3D printer
too.
To Configure it into STL file , we need another Software GRAB CAD.
GRAB CAD is the official software created by STRATSYS (the 3D-Printer making
company). It is compatible with any kind of modeling software.
It also enables us to vary the pattern of nozzle infilling
 ACTUAL MATERIAL

SUPPORT MATERIAL

SLICE HEIGHT /LAYER

THICKNESS

MATERIAL
ORIENTATION
SELECTION OF
EITHER FACE
/BODY

STRENGTH

RIGIDITY
TESTING AND REPORT

Surface preparation
At first the component is to be ready for the tribology testing
machine. Here first the component surface is prepared by making the
rough surface which was produced due to the printing process. For that
the component is rubbed over different grade size of sand papers.
When the component is smooth enough (by visual checking) then its
surface is cleaned from dust and dirt by applying a solution of acetone.
As all is done then the component is checked in weight as well as in
dimension also in order to carry out the testing procedure. All data
obtained are listed down so as to compare the object with the object
after testing.
 Testing
After all the pre fixing is done the object is placed in the tribo-testing
machine. Then suitable load is applied so as to measure different parameter
like co-efficient of friction, friction force, wear etc. Then suitable rpm is set
to rotate the drum which is in direct contact with the object. This process is
carried out for a certain period of time to get the sufficient amount of
deformation on the specimen.
 STANDARD MATERIAL PROPERTIES OF ABS

PRPERTY VALUES
TECHNICAL NAME Acrylonitrile butadiene styrene (ABS)
CHEMICAL FORMULA (C8H8)x· (C4H6)y·(C3H3N)z)
GLASS TRANSITION 105 °C (221 °F)
TYPICAL INJECTION MOULDING TEMP 204 - 238 °C (400 - 460 °F) *
HEAT DEFLECTION TEMPERATURE 98 °C (208 °F) at 0.46 MPa (66 PSI)

UL RTI 60 °C (140 °F)

TENSILE STRENGTH 46MPa
FLEXURAL STRENGTH 74MPa
SPECIFIC GRAVITY 1.06
SHRINK RATE 0.5/0.7%
 OBJECT :
 CALCULATE AND ANALYSE THE COEFFICIENT OF FRICTION UNDER DIFFERENT
PARAMETER
 CALCULATE AND ANALYSE THE FRICTIONAL FORCE WITH LOAD AND TIME

 ANALYSING THE WEAR IN THE MATERIAL.

 REPORT AND RESULTS

Table 1: Tribological study data of ABS material in parametric combination

Sl. Factors Dimensional Deviation Weight COF Wear

No. Infill Infill Layer Infill x y z Loss (micron)
Angle Density Thickness Pattern (mm) (mm) (mm) (gm)
(inch)

1 90 45% 0.007 Single +0.07 +0.01 +0.06 0.005 1.06 122

2 90 45% 0.007 Double 0 +0.03 +0.03 0.007 6.02 84
3 90 45% 0.013 Single +0.10 +0.02 +0.30 0.002 6.98 110
4 90 45% 0.013 Double +0.09 +0.06 +0.31 0.005 1.15 134
5 90 80% 0.007 Single +0.05 0 +0.08 0.004 3.30 154
6 90 80% 0.007 Double -0.05 0 +0.07 0.006 5.26 131
7 90 80% 0.013 Single 0 -0.07 +0.34 0.003 7.77 140
8 90 80% 0.013 Double +0.02 -0.04 +0.44 0.003 6.12 131
9 45 45% 0.007 Single -0.03 -0.01 +0.17 0.004 7.71 90
10 45 45% 0.007 Double +0.12 +0.20 +0.01 0.004 4.25 85
11 45 45% 0.013 Single +0.05 +0.01 +0.26 0.002 7.36 77
12 45 45% 0.013 Double -0.07 +0.02 +0.26 0.005 6.71 111
13 45 80% 0.007 Single +0.01 +0.02 +0.16 0.004 5.31 108
14 45 80% 0.007 Double +0.06 +0.09 -0.03 0.004 5.04 99
15 45 80% 0.013 Single -0.06 -0.17 +0.33 0.003 4.94 143
16 45 80% 0.013 Double -0.23 -0.05 +0.47 0.006 5.97 83
Table 2: Tribological study data of PLA material in parametric combination

Sl. Factors Dimensional Deviation Weight COF Wear

No. Loss (micron)
(gm)
Infill Infill Layer Infill x y z
Angle Density Thickness Pattern (mm) (mm) (mm)
(inch)

1 45 22% 0.010 Single +0.18 +0.16 +0.49 0.008 4.06 452

2 45 22% 0.010 Single +0.17 +0.15 +0.52 0.004 4.66 237

3 90 22% 0.010 Single +0.08 +0.15 +0.49 0.006 4.73 413

4 90 22% 0.010 Single +0.12 +0.09 +0.50 0.005 4.79 453

VARIATION OF DIFFERENT PARAMETER WITH TIME

Specimn-ABS1
SPECIMEN 2
ABS3
ABS4
ABS5
ABS6
ABS7
ABS8
ABS9
ABS-10
ABS-11
ABA-12
PLA-1
PLA2
PLA-3
PLA-4
COMPARISION BETWEEN ABS AND PLA
 DICSUSSION ; Depending upon the material property, different material behaves
different. Here also for ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic
Acid) shows different results in tribology testing as they have different material
property. Not only that by varrying infill angle, indill density, layer thickness, infill
pattern etc for a same material in Fused Deposition Modeling process the output
varries. From the Result it is easily disclosed that in overall C.O.F increases with
increase in infill angle, but the wear remain same more or less

REFERENCES: https://www.stratasys.com/3d-printers/f123
https://www.sciencedirect.com/topics/materials-science/fused-deposition-modeling
https://www.livescience.com/39810-fused-deposition-modeling.html
https://3dprinting.com/what-is-3d-printing/
https://en.wikipedia.org/wiki/3D_printing
https://en.wikipedia.org/wiki/Tribology
https://professional.mit.edu/programs/short-programs/tribology
https://www.google.com/search?biw=1366&bih=625&tbm=isch&sa=1&ei=7B_lXfHEO8L
hz7sP5fq90A4&q=fdm+printing+full+form&oq=fdm+printing+full+form&gs_l=img.3...67
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