Influence of surface roughness parameters of additively manufactured die on the extrudates in polymer extrusion

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Abstract

Additive manufacturing (AM) provides flexibility for manufacturing complex geometries, allowing for the creation of streamlined die designs with free-form geometries. However, polymer-based AM dies (soft tooling) have mechanical and thermal properties limitations, which may impact their ability to withstand the process conditions involved in polymer extrusion. A study was conducted on carbon fibre (CF) and polyether-ether-ketone (PEEK) composite dies produced via the Fused Filament Fabrication (FFF) method. Experimental testing of CF-PEEK AM die in polymer extrusion was performed with acrylonitrile butadiene styrene (ABS) and polypropylene (PP) extruded material. The surface characterisation of the CF-PEEK AM die replica, and the extrudates were characterised using 3D optical and confocal microscopes. Surface roughness parameters used in this study are height parameters (Sa and S10z) and functional surface parameters (Spk and Svk). Despite the distinctive ripple features of the FFF process with the peaks and deep valleys, the surface roughness parameters (Sa, Spk, and Svk) of the extrudates, measured on both extruded materials, are 6-8 times lower compared to the CF-PEEK die. It was observed that the surface topography of CF-PEEK AM die only impacted the surface roughness of the extrudates, particularly at the beginning of the experiments. As the screw speed increased, process parameters and cooling processes started to play a more significant role, exerting a greater influence on the surface quality of the extrudates.
Original languageEnglish
Publication date2023
Number of pages2
Publication statusPublished - 2023
EventJoint Special Interest Group meeting between euspen and ASPE
Advancing Precision in Additive Manufacturing
- KU Leuven, Leuven, Belgium
Duration: 19 Sept 202321 Sept 2023

Conference

ConferenceJoint Special Interest Group meeting between euspen and ASPE
Advancing Precision in Additive Manufacturing
LocationKU Leuven
Country/TerritoryBelgium
CityLeuven
Period19/09/202321/09/2023

Keywords

  • Additive manufacturing
  • Soft tooling
  • Surface roughness
  • Extrudates

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