Investigation of drilling performance of PLA samples produced at different raster angles using the FDM method

Abstract

Additive manufacturing (AM) is an innovative production technology used to create parts using a layer-by-layer production method. The Fused Deposition Modeling (FDM) AM technique is particularly preferred due to its ability to provide flexible production and the availability of inexpensive materials. This method is frequently used in the automotive industry, medical and biomedical applications, and prototype production. However, despite its flexible production capabilities, it requires specific processing steps to improve post-production surface quality and dimensional accuracy. As a result of these processes, undesirable outcomes such as delamination, surface roughness, and high temperature formation may occur, depending on both the processing parameters and the production parameters. Therefore, it is necessary to examine both the AM production parameters and the processing parameters. The aim of this study is to examine the drilling performance of samples produced at different raster angles using the FDM technique made from polylactic acid (PLA) material. Therefore, three different samples were produced at raster angles of 0-45-90° and drilled at three different feed rates (0.1-0.15-0.2 mm/rev). The thrust force, delamination, temperature formation, and surface roughness changes were examined. The results showed that the thrust force increased with the increase in feed rate and raster angle, which in turn led to an increase in the amount of delamination. The increase in raster angle and feed rate also raised the temperature during drilling. Additionally, chips became wrapped around the chip evacuation channels of the cutting tool, and as the cutting tool attempted to push and remove the chips, it increased the surface roughness of the hole’s inner walls. Finally, the relationship between the dependent and independent variables in the experimental results was examined using ANOVA analysis, and it was found that the effects of feed rate and raster angle on thrust force were significant (p < 0.05).