On fabrication of acrylonitrile butadiene styrene-zirconium oxide composite feedstock for 3D printing-based rapid tooling applications
Nishant Ranjan, Rashi Tyagi, Ranvijay Kumar, Vinay Kumar
Abstract
The 3D-printed rapid tools are being used in finishing operations such as drilling, milling, broaching, roller burnishing, and other finishing operations that need anti-wear plastic composite materials. Zirconium oxide (ZrO 2 ) is one of the ceramic materials which is highly appreciated due to its anti-wear properties. This study aims to develop the ZrO 2 ceramic particles reinforced acrylonitrile butadiene styrene (ABS) thermoplastic composite feedstock filaments for 3D printing of rapid tools. In the first stage, the multiple numbers (as per Taguchi L 9 orthogonal array (OA)) of ABS-ZrO 2 feedstock filaments were developed by varying the loading of ZrO2 in ABS matrix (2 wt.%, 4 wt.%, and 6 wt.%), processing temperature (200, 205 and 210°C), and rotation speed of screw (4, 6 and 8 RPM). The optimum setting obtained for manufacturing ABS-ZrO 2 composite feedstock filaments is the combination of 2% ZrO2 loading, 205°C processing temperature, and 6 RPM screw speed. In the next stage, fused filament fabrication (FFF) based 3D printing has been used to prepare the rapid tools. The wear test performed for 3D printed ABS-ZrO 2 composites rapid tools shows only .62% weight loss which is lower as compared to virgin ABS (.91% weight loss). The results of the study are supported by fracture analysis, morphology, and mechanical properties.