International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 7, Issue 6, Dec 2017, 45-52
© TJPRC Pvt. Ltd

EXPERIMENTAL INVESTIGATION ON INFLUENCE OF PROCESS

PARAMETERS IN SELECTIVE LASER SINTERING ON

ROUNDNESS USING TAGUCHI MEDTHOD

M. NAVEEN KUMAR1, SRIRAM VENKATESH2 & M. MANZOOR HUSSAIN3

1
Department of Mechanical Engineering, Vidya Jyothi Institute of technology, Aziz Nagar, Hyderabad, India
2
Department of Mechanical Engineering, Osmania University, Hyderabad, India
3
Department of Mechanical Engineering, JNTUH Hyderabad, India
ABSTRACT

Additive Manufacturing is emerging latest trends, in todays industrial needs. The 3D model is built by using
the Catia V5 and exported to Rapid Prototyping machine where the file is saved by. stl extension and the file repair was
done by removing the facets using magics software. The 3D model is sliced into layers and build layer by layer using
PA2200 material in powder form and sintered with co2 laser by controlling the process parameters. This research
investigates the effect of the roundness of the prototype model built on Rapid Prototyping machine by optimal selection

Original Article
of process parameters like laser power, layer thickness and temperature by Taguchi design of experiments approach L9
Orthogonal array was selected lower-the-better signal-to-noise S/N ratio. Analysis of Variance (ANOVA) with regression
model is also conducted and most influential parameter in decreasing order Laser power, Layer thickness, and
temperature were obtained and the prototypes are tested on CMM (coordinate measuring machine) both the
experimental and model prediction results are within close tolerance of +/- 0.029 (29 microns) on the roundness.

KEYWORDS: Additive Manufacturing, 3D model, Rapid Prototyping Machine, orthogonal array, ANOVA, S/N ratio,
sintering, PA2200, CMM, tolerance

Received: Sep 19, 2017; Accepted: Oct 09, 2017; Published: Oct 30, 2017; Paper Id.: IJMPERDDEC20174

INTRODUCTION

Rapid prototyping is an Additive Manafacuring technique in which the solid model is built by addition of
material where the model is built using Catia V5 software and saved with the file extension. iges or. Step and
exported to the Rapid prototyping machine where the file is converted to. stl. After converting to. stl is the file is
repaired by using another software magics all the facets are removed and then the model is sliced into layers with
layer thickness and build layer by layer using polyamide material PA2200 in powder from and sintered by co2
laser This technology is used for various materials plastics, metals, copper, aluminium etc., [1]. The principle of
selective laser sintering process is the powder layer is placed on the bed of Rapid prototype machine with the help
of rollers and sintered by laser and the bed is moved down by an amount of layer thickness and one more layer is
placed over the previous sintered layer and thus the model is built layer by layer [5] as shown in the figure.
Selective laser sintering process is used for producing functional parts with in short period of time and cost and
ready to market the product where the ideas are easily implemented and prototype models are produced [3-6] The
parts produced have less surface finish and roundness lot of work done on surface finish but less work is done on
roundness so the present research work this paper is focused on roundness by varyng the process parameters using

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46 M. Naveen Kumar, Sriram Venkatesh & M. Manzoor Hussain

taguchi design of experiments of orthogonal array and tested on CMM (Cordinate Measuring Machine).

LITERATURE SURVEY

Mayer [10] done work on surface methodology process and product optimization using design of experiments [1]
Pandey and Senthilkumaram have done on part accuracy and shrinkage influence by process parameters of the selective
laser sintering process [2] Sercombe, T, B Hopkinson has done on metals like aluminium about part shrinkage and
accuracy [7] Ning, Y.; Wong, Y. S.; Fuh, worked on minimized the build errors in metals [8] Wenbin, H.; Tsui, L. Y.;
Haiqing done staircase effect induced by part shrinkage in RPT machine. [9]. Ning, Y.; Fuh, J. Y. H.; Wong, Y. S.; Loh, H.
T. Worked on the parameter selection system for the direct metal laser sintering process. [3] Raghunath, N Pandey done
work on improving the accuracy through shrinkage modeling by using Taguchi method in the selective laser sintering
process [12] Anish Sachdeva & Sharanjit Singh done on surface roughness by using sls. After analyzing the literature
survey accuracy of the part is dependent process parameters like power, scan speed, layer thickness, temperature, etc.
highly related to the shape and size of the components produced by the selective laser sintering process. The present
research work is on the roundness by optimizing the process parameters like laser power, layer thickness and bed
temperature enhance the quality of the component produced by sls.

Figure 1: Principle of Selective Laser Sintering Process

Figure 2: Rapid Proto typing Machine

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Experimental Investigation on Influence of Process Parameters in Selective Laser Sintering on 47
Roundness Using Taguchi Medthod

Figure 3 and 4: Samples of sls Process and 3D CAD Model

EXPERIMENTATION

The parameter settings like laser power, layer thickness and temperature beds at different levels are shown in
table1. The reasons roundness is shown in table 2. A total of nine (9) experiments were conducted, using taguchie design of
experiments approach orthogonal array and tested using CMM (Coordinate Measuring Machine). The material used to
build the prototypes is Polyamide PA2200, in the powder form and sintered by co2 laser with controlled process
parameters. All the fabricated prototypes, using selective laser sintering process, by varying the process parameters built
are shown in the figure 3 and the 3D model is created by using Catia V5 Shown figure 4.

Table 1: Levels of Process Parameters

PARAMETERS DESIGNATION UNITS LEVEL 1 LEVEL 2 LEVEL 3
LASER POWER P WATT 67 68 70
LAYER
L MICRONS 100 110 120
THICKNESS
DEGREE
TEMPERATURE T CEBTIGRA 174.7 175 176
DE

Table 2: Experimental Results of Orthogonal Arrray of L9 for Roundness

EXPEREIMENT LASER LAYER
TEMPERATURE ROUNDNESS
RUN POWER THICKNESS
1 1 1 1 0.0954
2 1 2 2 0.0388
3 1 3 3 0.0458
4 2 1 2 0.0673
5 2 2 3 0.0784
6 2 3 1 0.0548
7 3 1 3 0.0383
8 3 2 1 0.0292
9 3 3 2 0.0524

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48 M. Naveen Kumar, Sriram Venkatesh & M. Manzoor Hussain

Table 3: S/N Ratio of Each Parameter and Level for Roundness

Experimental Mean Roundness S/N Ratio Average S/N Delta
Parameter Level Rank
Run Microns dB Ratio dB (max-min)
1 0.0954 20.409
1 2 0.0388 28.223 25.138
3 0.0458 26.782
4 0.0673 23.439
P 2 5 0.0784 22.113 23.592 4.62 1
6 0.0548 25.224
7 0.0383 28.336
3 8 0.0292 30.692 28.213
9 0.0524 25.613
1 0.0954 20.409
1 4 0.0673 23.439 24.061
7 0.0383 28.336
2 0.0388 28.223
L 2 5 0.0784 22.113 27.009 2.94 2
8 0.0292 30.692
3 0.0458 26.782
3 6 0.0548 25.224 25.873
9 0.0524 25.613
1 0.0954 20.409
1 6 0.0524 25.224 25.441
8 0.0292 30.692
2 0.0388 28.223
T 2 4 0.0673 23.439 25.758
9 0.0524 25.613 0.31 3
3 0.0458 26.782
3 5 0.0754 22.113 25.743
7 0.0383 28.336
sum 1.4958 230.828
Average 0.0554 25.6475

Table 4: For Maximum Andminimum Influence Anom (Analysis of Mean)

LAYER
LEVELS POWER TEMPERATURE
THICKNESS
LEVEL1 0.180 0.201 0.162
LEVEL2 0.200 0.146 0.158
LEVEL3 0.119 0.153 0.179
RANGE 0.081 0.055 0.021

RESULTS AND DISCUSSIONS

After the results obtained from the experiements taguchi quality indes lower – the - better S/N ratio, in dB was
used to find the optical process parameter, Lower=the=better.

S/N ratio = -10log10 (1/n ΣY2)) n= recurrence =1 and Y is the measured roundness, for each trial.

The table provides the calculated values of S/N ratio and the average S/N ratio, for all the parameters and its
levels. To achieve the roundness of polyamide parts produced by sls process, the maximum of the S/N ratio to reduce the
loss function and better the quality, and the optimal process parameters are obtained shown in the table. The figures 5-13
shows the main effect of process parameters, on the S/n ratio at all levels. Optimization of control factors ANOM (Analysis
of Mean) at all the three levels, for each factor.

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Experimental Investigation on Influence of Process Parameters in Selective Laser Sintering on 49
Roundness Using Taguchi Medthod

Laser Power Level 3 70 watts Layer Thickness level 2 110 Microns Temperature level 2 175 Degree Centigrade as
shown in figures

optimum level of mean laser power optimum level of m ean layer thickness

0.250
0.25
avg roundness

0.200
0.2

avg rou ndness

0.150 0.15
P L
0.100 0.1
0.05
0.050

0
0.000
0 0.5 1 1.5 2 2.5 3 3.5 0 1 2 3 4

levels levels

Figure 5: Laser Power Figure 6: Layer Thickness

optimum level of mean temperature EFFECT OF POWER ON S/N RATIO

0.185
0.18 40
avg ro u n d n ess

0.175 S /N R A T IO d B 30
0.17 T Series1
20
0.165 Series2
10
0.16
0.155 0
0 1 2 3 4 67 67 67 68 68 68 70 70 70

levels LEVELS OF LASER POWER Watt

Figure 7: Temperature T Figure 8: S/N ratio vs Laser Power

EFFECT OF LAYER THICKNESS ON S/N RATIO EFFECT OF TEMPERATURE S/N RATIO

35

30
40
S/N R A T IO S d B

30 25

Series1
20 20
Ser ies1
Series2 Ser ies2
10 15

0 10

100 100 100 110 110 110 120 120 120 5

LEVELS OF LAYER THICKNESS 0

175 175 175 175 175 175 176 176 176
MICRONS L EVEL S O F T EM P I N C EN T I G R A D E

Figure 9: S/N ratio vs Layer Thickness Figure 10: S/N ratio vs Temperature

EFFECT OF LASERPOWER ON ROUNDNESS EFFECT OF LAYER THICKNESS ON ROUNDNESS

0.12
0.12
R O U N D N E S S IN

0.1
0.0954 0.1 0.0954
M IC R O N S

0.08 0.0784 0.08 0.0784

0.0673 Series1
0.0673 0.06 0.0548
0.0458 0.0524
0.06 Series1
0.0548 0.0524 0.04 Series2
0.0458 0.03830.0388
0.04 0.0388 0.0383 0.0292
0.0292 0.02
0.02 0
0 100 100 100 110 110 110 120 120 120
67 67 67 68 68 68 70 70 70
LEV ELS OF LA SER LA SER PO W ER W at t LEVELS OF LAYER THICKNESS IN MICRINS

Figure 11: Roundness vs Laser Power Figure 12: Roundness vs Layer Thickness

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50 M. Naveen Kumar, Sriram Venkatesh & M. Manzoor Hussain

EFFECT TEMPERATURE ON ROUNDNESS

RO UNDNESS IN MICRONS
0.12
0.1 0.0954
0.08 0.0754
0.0673 Series1
0.06
0.0524 0.0524 Series2
0.0458
0.04 0.0388 0.0383
0.0292
0.02

0
175 175 175 175 175 175 176 176 176
LEVELS OF TEMP IN CENTIGRADE

Figure 13: Roundness vs Layer Thickness

ANOVA (Analysis of Variance) for ROUNDNESS

Table 5: Analysis of Variance

Source DF Adj SS Adj MS F-Value P-Value
LP 2 0.001170 0.000585 0.66 0.604
LT 2 0.000592 0.000296 0.33 0.751
T 2 0.000082 0.000041 0.05 0.956
Error 2 0.001782 0.000891
Total 8 0.003626

Table 6: Model Summary

S R-sq R-sq (adj) R-sq (pred)
0.0298514 50.85% 0.00% 0.00%

Table 7: Coefficients of Regression

Term Coef SE Coef T-Value P-Value VIF
Constant 0.05560 0.00995 5.59 0.031
LP
1 0.0044 0.0141 0.31 0.784 1.33
2 0.0112 0.0141 0.80 0.508 1.33
LT
1 0.0114 0.0141 0.81 0.503 1.33
2 -0.0068 0.0141 -0.48 0.677 1.33
T
1 0.0042 0.0141 0.30 0.794 1.33
2 -0.0028 0.0141 -0.20 0.862 1.33

Table 8: Regression Equation

0.05560 + 0.0044 LP_1 + 0.0112 LP_2 - 0.0156 LP_3 + 0.0114 LT_1 - 0.0068 LT_2 - 0.0046 LT_3 + 0.0042 T_1 -
Roundness =
0.0028 T_2 - 0.0014 T_3

Roundness from the regression model, in microns 0.0172.

Confirmation Test

This research paper is to validate the model equation, confirmation experiment and S/N method were adopted at
optimum level and the table, shows the experimental and predicted values are compared at optimum settings, on the
roundness.

The predicted value of roundness is calculated from the of S/N ratio, at optimum settings.

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Experimental Investigation on Influence of Process Parameters in Selective Laser Sintering on 51
Roundness Using Taguchi Medthod

S/Npredicted = S/Nmean + ( S/Ni - S/Nmean) 25.652 = -10logY2 Y= 0.052 microns.

Predicted Model

The predictive model is constructed from the results of the orthogonal array analysis and it is formed by the
optimum level of contribution of each factor related to deviation from overall mean is,

Y(P,L,T) = Ymean + (Ymean P - Ymean ) + (Ymean L - Ymean ) + (Ymean T - Ymean ) at optimum parameters.

Y (P3 L2 T2) = 0.0556 + (0.039 -0.0556) + 0.048-0.0556) + (0.052 -0.0556)

= 0.0296 approx 30 microns.

Comparison between the experimental value, regrssion value, predicted S/N ratio and mean value

Table 9: Comparisson Experimental and Predicted Values

Laser Layer Experimental Predicted S/N Mean Regression
Parameter Temperature
Power thickness value value value Value
Optimal 110
70 watts 175ºC 0.0292 0.052 0.0296 0.0172
setting microns

CONCLUSIONS

The influence of process parameters on the roundness of polyamide parts, built by a selective laser sintering
process, by Taguchi design of experiments L9 orthogonal array approach and the roundness of the parts was found out by
experimental value, S/N ratio, regression value and mean value it was found that, close tolerance 30-55 microns were
obtained, with the optimization process parameters.

• The optimal parameters Laser power has maximum influence, layer thickness medium and temperature minimum
influence.

• Confirmation model results roundness, approx to 30 microns.

• Experimental value on roundness with optimal process parameter is about 29 microns.

• S/N ratio value on roundness is 52 microns.

• The results after comparison, there are variation 25 microns from mathematical and experimental values.

ACKNOWLEDGEMENT

The author is thankful to CITD Balanagar, Hyderabad, for the prototyping, testing on CMM Coordinate measuring
machine.

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Impact Factor(JCC) :6.8765 NAAS Rating : 3.11