Enhancing Surface Finish in FDM 3D Printing: The Impact of a Spherical Ironing Tool

Abstract:

This study aims to evaluate the functionality and effectiveness of a new tool for ironing 3D printed components using FDM technology. The ironing process draws inspiration from the ball burnishing process, employing a spherical tool that, by exerting pressure, modifies the component's surface. The process involves heat transfer between the tool and the component to soften and deform the surface more easily. A theoretical analysis of the resulting surface roughness following this process was conducted to identify the parameters at play and their influence. It was found that the two main parameters are the fillet radius and the distance between passes. Additionally, practical tests were carried out to confirm the hypotheses, revealing the influence of three other parameters: tool Z-axis positioning, temperature, and movement speed. The surface after treatment exhibits an average roughness of Ra = 0.378 μm, significantly better than values obtained with ironing performed with the nozzle and with quality comparable to grinding. This lays the groundwork for possible future optimization of parameters based on the component's characteristics and the material used.

• Periodical: Key Engineering Materials (Volume 996)
• Pages: 61-66
• DOI: https://doi.org/10.4028/p-iZS52G
• Online since: December 2024
• Authors: Andrea Montalti*, Giulio Galiè, Alfredo Liverani
• Keywords: Additive Manufacturing, Burnishing, FDM, Ironing, Surface Treatment

References

[1] A. Nigam and B. L. Tai, "Effects of in-process surface finishing on part strength in polymer material extrusion additive manufacturing," Addit Manuf, vol. 80, p.103960, Jan. 2024.

DOI: 10.1016/j.addma.2024.103960

[2] Torres, J., Abo, E. and Sugar, A.J. (2023), "Effects of annealing and acetone vapor smoothing on the tensile properties and surface roughness of FDM printed ABS components", Rapid Prototyping Journal, Vol. 29 No. 5, pp.921-934

DOI: 10.1108/RPJ-03-2022-0088

[3] A. A. Demircali, D. Yilmaz, A. Yilmaz, O. Keskin, M. Keshavarz, and H. Uvet, "Enhancing mechanical properties and surface quality of FDM-printed ABS: A comprehensive study on cold acetone vapor treatment," The International Journal of Advanced Manufacturing Technology, vol. 130, no. 7–8, p.4027–4039, Feb. 2024.

DOI: 10.1007/s00170-023-12929-2

[4] N. Sathishkumar, N. Arunkumar, L. Balamurugan, L. Sabarish, and A. Samuel Shapiro Joseph, "Investigation of Mechanical Behaviour and Surface Roughness Properties on Copper Electroplated FDM High Impact Polystyrene Parts," in Lecture Notes on Multidisciplinary Industrial Engineering, vol. Part F164, 2020.

DOI: 10.1007/978-981-32-9433-2_25

[5] A. W. Hashmi, H. S. Mali, A. Meena, S. Ahmad, and Y. Tian, "A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN," Rapid Prototyp J, vol. 29, no. 10, 2023.

DOI: 10.1108/RPJ-04-2023-0136

[6] B. Taghizadeh, M. V. Ehteshamfar, and H. Adibi, "Lapping optimization of additively manufactured ABS-carbon fiber composite parts using the soft computing technique," Polym Test, vol. 128, p.108241, Nov. 2023.

DOI: 10.1016/j.polymertesting.2023.108241

[7] S. Swirad, "Changes in Areal Surface Textures Due to Ball Burnishing," Materials, vol. 16, no. 17, 2023.

DOI: 10.3390/ma16175904

[8] A. Sood and B. Mullany, "Advanced surface analysis to identify media-workpiece contact modes in a vibratory finishing processes," in Procedia Manufacturing, 2021.

DOI: 10.1016/j.promfg.2021.06.077

[9] M. R. Khosravani, M. R. Ayatollahi, and T. Reinicke, "Effects of post-processing techniques on the mechanical characterization of additively manufactured parts," J Manuf Process, vol. 107, p.98–114, Dec. 2023.

DOI: 10.1016/j.jmapro.2023.10.018

[10] J. S. Dai, P. M. Taylor, P. Sanguanpiyapan, and H. Lin, "Trajectory and orientation analysis of the ironing process for robotic automation," International Journal of Clothing Science and Technology, vol. 16, no. 1–2, 2004.

DOI: 10.1108/09556220410520496

[11] M. Sardinha, J. Lopes, A. Gusmão, L. Reis, and M. Leite, "Ironing process influence on the warping of ABS parts produced by Fused Filament Fabrication," in Procedia Structural Integrity, 2022.

DOI: 10.1016/j.prostr.2022.12.162

[12] M. Caputo, O. Rashwan, D. Waryoba, and K. McDade, "Surface texture and thermo-mechanical properties of material extruded and ironed polylactic acid," Addit Manuf, vol. 59, 2022.

DOI: 10.1016/j.addma.2022.103084

[13] J. D. Kechagias and S. P. Zaoutsos, "An investigation of the effects of ironing parameters on the surface and compression properties of material extrusion components utilizing a hybrid-modeling experimental approach," Progress in Additive Manufacturing, Nov. 2023.

DOI: 10.1007/s40964-023-00536-2

[14] H. Alzyod, J. Takacs, and P. Ficzere, "Improving surface smoothness in FDM parts through ironing post-processing," Journal of Reinforced Plastics and Composites, Apr. 2023.

DOI: 10.1177/07316844231173059

[15] H. García de la Torre, G. Gomez-Gras, A. Chueca de Bruijn, and M. A. Pérez-Martínez, "Enhancement of mechanical and surface properties by ball burnishing process on polymeric components obtained by FFF," Rapid Prototyp J, vol. 29, no. 8, 2023.

DOI: 10.1108/RPJ-12-2022-0424

[16] B. Neuhaus, M. K. Idris, P. Naderi, Y. El‐Hajj, and G. Grau, "Low‐Roughness 3D‐Printed Surfaces by Ironing for the Integration with Printed Electronics," Adv Eng Mater, Jan. 2024.

DOI: 10.1002/adem.202301711