Mechanical Performance of Pattern Using 3d Printing Process

MECHANICAL PERFORMANCE OF PATTERN
USING 3D PRINTING PROCESS
19ME705 PROJECT PHASE II

Name Register Number Department
BALAJI R 212219080010 MECHANICAL
NITISH MISHRA 212219080061 MECHANICAL
S.KANAKA SAI 212219083008 MECHANICAL

VARAHALU
Guided by: Dr.N.RAJA RAJESWARI, M.E., PhD.,

OUTLINE OF CONTENT
 ABSTRACT
 INTRODUCTION
 LITERATURE REVIEW
 OBJECTIVES
 METHODOLOGY
 DESIGN STEPS
 APPLICATION
 ANALYSIS
 CONCLUSION
ABSTRACT
 The mechanical performance of patterns is an important consideration in many

industrial applications. With the advent of 3D printing technology, it has become
easier and more cost-effective to produce complex patterns with intricate
geometries.
 The mechanical properties of 3D printed patterns can be influenced by factors such

as printing parameters, design, and material properties. Finite Element Analysis
(FEA) can be used to simulate the mechanical behavior of patterns and predict their
performance under different loading conditions.
 This project investigates the mechanical performance of patterns produced using a

3D printing process with FEA analysis.
 A set of standardized samples were designed, printed, and tested in order to

evaluate their mechanical properties.
ABSTRACT
 The FEA simulations were conducted to analyze the stress and strain distributions
in the patterns and to predict their behavior under different loading conditions.
 The results of the project demonstrate that FEA is a valuable tool for predicting the
mechanical performance of 3D printed patterns.
 The simulations were found to be consistent with the experimental results, which
validates the accuracy of the FEA models.
 The simulations also provide insights into the effects of printing parameters and
design on the mechanical performance of patterns.
INTRODUCTION
 Three-dimensional (3D) printing is getting important in the product development

sector for industrial manufacturing. By using 3D printing, able to produce complex
prototype products with advanced functions parameters like the variety of printer
speed, temperature, infill pattern.
 Layer height, filling percentage, build orientation, infill pattern, raster direction
angle, extrusion temperature, air gaps, deposition speed, and contour width are
among the settings for 3D printing processes that have received the most research.
 A form of photopolymer resin used in 3D printing is called V4 black resin

substance. For usage in high-resolution stereolithography (SLA) printers, it is
especially made. The smooth surface finish of the V4 black resin material makes it
perfect for making intricate and detailed items, such as jewellery and tiny figurines.
INTRODUCTION
 The high level of accuracy of V4 black resin material, which enables accurate and
detailed printing, is one of its important characteristics. Moreover, it has very good
dimensional stability, which guarantees that printed parts maintain their size and
shape over time.
 The process of constructing a physical model or template that is used to build a

mould for casting or moulding a specific object or part is referred to as pattern
making in mould. Typically, the pattern is created from a range of materials, such
as wood, metal, or plastic, and is intended to have the precise shape and
measurements of the finished product.
 Pattern making is an important step in the manufacturing process, as it ensures that

each part is consistent in size and shape and can be mass-produced efficiently.
LITERATURE REVIEW
S.N0 PUBLISH YEAR TITLE NAME OF

AUTHORS
1 2021 The influence of 3D printing process parameters Muammel
on the mechanical performance of PLA polymer M. Hanon
and its correlation with hardness.
2 2022 Effect of FDM infill patterns on mechanical Márton

properties Tamás Birosz
3 2021 Study of photocurable energetic resin based Manman Li,
propellants fabricated by 3D printing Weitao Yang
4 2018 Surface defect identification and measurement Ulises Galan

for metal castings by vision system
5 2016 Analyzing Decision-making in Automotive Alexander Kaluza

Design towards Life Cycle Engineering for
Hybrid Lightweight Components.
OBJECTIVE
 Aims to analyze and design an additive manufacturing pattern using 3D printing.
 The stereolithography (SLA) technique was used to fabricate testing specimens

with different build orientations of material. FEA analysis was conducted on
specimens and fracture patterns were specified.
 A correlation between hardness and tensile strength was assessed based on the
performance attained from the examined print parameters.
 This correlation indicates the need for evaluating this correlation to understand the
3D Fabricated material behavior entirely.
 The molding process involves melting a plastic material and injecting it into a
mold, which is then cooled and injected to produce the desired shape.
METHODOLOGY
FLOW CHART
METHODOLOGY
PRINTING MACHINE
(FORMLABS FORM3)
DESIGN STEPS
 How to 3d print.
Depending on the specific print you are planning to do there could be more or
fewer steps in your process. But in general, 3D printing involves the
following actions.
 Step 1: Create or Find a Design
The first step of 3D printing typically starts on a computer. You must create your
design using a 3D design software, typically a CAD (computer-aided design)
software. If you are unable to create the design yourself, you can also find many
free resources online with free designs.
 Step 2: Export the STL File
Once you have created or chosen a design, you must either export or download the
STL file. The STL file is what stores the information about your
conceptual 3D object.
 Step 3: Choose Your Materials
Typically you may have an idea about what kind of material you will use before
you print. There are many different 3D printing materials.
DESIGN STEPS
 Step 4: Choose Your Parameters

The next step is then deciding on the different parameters of your object and the
printing process. This includes deciding on the size and placement of your print.
 Step 5: Create the G code
You will then import the STL file into a slicing software, like BCN3D Cura. The
slicing software will convert the information from the STL file into a G code,
which is a specific code containing exact instructions for the printer.
 Step 6: Print This is when the
magic happens! The printer will create the object layer by layer. Depending on the
size of your object, your printer, and the materials used, the job can be done in a
matter of minutes or over several hours. Depending on what you want your final
product to be or the material you used, there may be additional post-processing
steps after printing, like painting, brushing off powder, etc.
DESIGN
PRINTED SPECIMENT II
PRINTED SPECIMENT I
PRINTED SPECIMENT III

DESIGN STEPS
POST-PROCESS CREATE THE SAND

PRINT OF THE PATTERN OF THE PATTERN MOLD
INJECTING PROCESS POST-PROCESS OF

THE METAL CAST
APPLICATION
 CHASSIS
 The chassis is the framework or structure that supports all the components of an
automobile. It is usually made of steel, but other materials like aluminum and
carbon fiber can also be used.
 It includes the frame, suspension system, steering system, and brakes, and plays a
critical role in determining the performance and handling of a car.
 Automakers invest significant time and resources in designing and testing the
chassis to ensure it meets their performance and safety standards.
 A pattern mold provides consistency, precision, efficiency, reusability, and cost-

effectiveness for high volume production. It allows for precise measurements and
dimensions, faster and more efficient production, and reusability.
APPLICATION
CHASSIS
ANALYSIS
LIST OF TEST
 TENSILE TEST
Tensile tests are used to measure the behavior of a material under tension.
They involve placing a specimen in a testing machine and gradually
pulling it apart by applying an increasing tensile force. The data collected
during a tensile test is used to calculate a number of material properties,
including yield strength, ultimate tensile strength, ductility, and modular of
elasticity. Tensile testing is an important tool for quality control and
product development in industries such as manufacturing, aerospace, and
automotive engineering, helping engineers select the right materials for
specific applications and ensure that materials meet design specifications.
ANALYSIS
 TENSILE TEST
Time Strain Stress Displacem
ent
(s) (N/mm2)
(mm)
0 0 0 0
1 0.00260828 10433.1 0.1664
2 0.00522476 20899 0.333597
3.5 0.00916501 36660 0.585907
5.75 0.0151108 60443.2 0.967823
9.125 0.0241095 96437.7 1.54857
14.1875 0.0377945 151177 2.43802

TENSILE TEST GRAPH
20 0.0537924 215167 3.48744
TABLE TENSILE TEST

ANALYSIS
STRESS DISTRIBUTION OBSERBED ON A REPRESENTATION OF DEFLECTION ON THE

TENSILE TEST TENSILE TEST
DOGRAHMIC STRAIN
ANALYSIS
 COMPRESSION TEST
Time Displacement Stress Strain
(s) (mm) (N/mm2)
0 0 0 0
1 0.0388602 0.000393115 7418.41
2 0.0775919 0.000785335 14839.2
3.5 0.13545 0.00137186 25977.1
5.75 0.221704 0.0022476 42699.1
9.125 0.349902 0.00355211 67816.4
14.1875 0.539621 0.00548839 105571
20 0.753514 0.007683 149023

TABLE FOR COMPRESSION COMPRESSION TEST GRAPH
ANALYSIS
STRESS DISTRIBUTION REPRESENTATION OF

OBSERVED ON THE DEFLECTION ON THE DOGRAHMIC STRAIN
COMPRESSION TEST COMPRESSION TEST
ANALYSIS
 BRINELL HARDNESS TEST

MATERIAL DENSITY YOUNGS MAXIMUM MAXIMUM DEFLECTION
NAME MODULUS STRESS STRAIN
KG/MM3
N/MM2
WOOD 0.000000500 9000000 +4251e+02 +2229e-05 +6487e-04
PLA 1.24*10-6 7000000 +4251e+02 +1751e-05 +5097e-04
COPPER 8.96*10-6 7000000 +4251e+02 +1048e-06 +3050e-05
V4 BLACK 1.4*10-6 4000000 +4251e+02 +3064e-05 +8920e-04
RESIN
ANALYSIS
BLACK RESIN- STRESS DISTRIBUTION BLACK RESIN- REPRESENTATION OF

OBSERVED DEFLECTION
BLACK RESIN- DOGRAHMIC STRAIN

CONCLUSION AND FUTURE WORK
 This project evaluated the mechanical performance of patterns produced using a 3D

printing process. The results showed that 3D printing is a viable method for
producing patterns with good mechanical performance.
 The tensile and compressive strengths of the printed patterns were comparable to
those of traditionally manufactured patterns, and the fatigue life was within
acceptable limits.
 FEA simulations were found to be consistent with the experimental results,

validating the accuracy of the FEA models.
 The findings of this project can be used to optimize the design and printing
parameters of 3D printed patterns to achieve desired mechanical properties.
Thank you

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MECHANICAL PERFORMANCE OF PATTERN

USING 3D PRINTING PROCESS

19ME705 PROJECT PHASE II

NITISH MISHRA 212219080061 MECHANICAL

S.KANAKA SAI 212219083008 MECHANICAL

Guided by: Dr.N.RAJA RAJESWARI, M.E., PhD.,

 The mechanical performance of patterns is an important consideration in many

 The mechanical properties of 3D printed patterns can be influenced by factors such

 This project investigates the mechanical performance of patterns produced using a

 A set of standardized samples were designed, printed, and tested in order to

 Three-dimensional (3D) printing is getting important in the product development

 A form of photopolymer resin used in 3D printing is called V4 black resin

 The process of constructing a physical model or template that is used to build a

 Pattern making is an important step in the manufacturing process, as it ensures that

S.N0 PUBLISH YEAR TITLE NAME OF

2 2022 Effect of FDM infill patterns on mechanical Márton

4 2018 Surface defect identification and measurement Ulises Galan

5 2016 Analyzing Decision-making in Automotive Alexander Kaluza

 Aims to analyze and design an additive manufacturing pattern using 3D printing.

 The stereolithography (SLA) technique was used to fabricate testing specimens

 Step 4: Choose Your Parameters

PRINTED SPECIMENT III

POST-PROCESS CREATE THE SAND

INJECTING PROCESS POST-PROCESS OF

 A pattern mold provides consistency, precision, efficiency, reusability, and cost-

1 0.00260828 10433.1 0.1664

2 0.00522476 20899 0.333597

3.5 0.00916501 36660 0.585907

5.75 0.0151108 60443.2 0.967823

9.125 0.0241095 96437.7 1.54857

14.1875 0.0377945 151177 2.43802

TABLE TENSILE TEST

STRESS DISTRIBUTION OBSERBED ON A REPRESENTATION OF DEFLECTION ON THE

(s) (mm) (N/mm2)

1 0.0388602 0.000393115 7418.41

2 0.0775919 0.000785335 14839.2

3.5 0.13545 0.00137186 25977.1

5.75 0.221704 0.0022476 42699.1

9.125 0.349902 0.00355211 67816.4

14.1875 0.539621 0.00548839 105571

20 0.753514 0.007683 149023

STRESS DISTRIBUTION REPRESENTATION OF

 BRINELL HARDNESS TEST

BLACK RESIN- STRESS DISTRIBUTION BLACK RESIN- REPRESENTATION OF

BLACK RESIN- DOGRAHMIC STRAIN

 This project evaluated the mechanical performance of patterns produced using a 3D

 FEA simulations were found to be consistent with the experimental results,

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