Comparative study of process parameters’ influence on geometric accuracy and relative errors of lightweight compound gear printed by vat. photopolymerization and material extrusion

• DOI: 10.1016/j.jer.2024.03.018
• Publication Date: 2024-04-04T04:44:23Z
• Authors: Zeeshan Hamid Malik; Achmad Pratama Rifai; Muhammad Akhsin M...

Plastic and polymer composite gears are gaining popularity due to their cost-effectiveness, lightweight properties, quiet operation compared metal gears. Additive manufacturing has transformed the production of gears, impacting dynamic behavior. However, determining optimal printing conditions remains a subject ongoing research. In this study compound gear for well-zoom filament extruder machine was 3D printed using two different three-dimensional techniques, namely vat photopolymerization material extrusion. Taguchi L9 array created 2 factors at 3 levels selected process parameters VPP (layer height, exposure time) MEX extruding temperature) Minitab software, both methods employed orientation 45o, while all other remained constant. A total 54 were printed, with focus on identifying achieve minimal geometric errors. new approach digital microscopy applied, sector span measurement subsequent parameter calculations like base pitch pb, circular thickness Sb, tip diameter da, root df, p single deviation fpt. The study, identified include layer height 100 μm an time 6 s, resulting in relative errors less than 1.73% span, 3.25% thickness, 1.34% diameter, 0.09% diameter. Similarly, MEX, temperature 210°C yield favorable results, 0.43% 1.45% 1.42% 0.17%