International Journal of Structural Mechanics and Finite Elements
Hybrid ABS & CF-ABS FDM Printing Tensile Components: A Comprehensive Review and a Novel Taguchi–FEA Based Methodology Framework for Mechanical Optimization
1 Research Scholar , Department of Mechanical Engineering, Sarvepalli Radhakrishnan University, Bhopal- 462026, Madhya Pradesh, India.
2 Professor, Department of Mechanical Engineering in RKDF Institute of Science & Technology, Sarvepalli Radhakrishnan University Bhopal-462026, Madhya Pradesh, India.
Abstract
Abstract
An experimental–numerical strategy and a critical literature survey were addressed to tackle the tensile response of hybrid Acrylonitrile Butadiene Styrene (ABS) and Carbon Fiber–reinforced ABS (CF-ABS) parts manufactured by Fused Deposition Modeling (FDM). The study employed a systematic literature synthesis to identify material challenges, reinforcement compromises and important process parameters that impact anisotropy as well as interlayer bonding. Dual-material tensile samples based on an Automatic Material System (AMS) printer were designed and manufactured. DOE was conducted via using Taguchi L25 orthogonal array for single-material experiments and L8 array did the same job for other hybrid set ups with validations through FEA. The neat one demonstrated ductile behavior, with UTS of 8.76 MPa and as long as 52.65 % elongation at break, while the other showed lower UTS (39.71 MPa) and only 12.33 % elongation. Hybrid specimens exhibited a non-optimal mechanical behaviour with a strength 32–45 % higher than for pure ABS and an increase of the ductility by 25–35 % in comparison to CF-ABS. The hybrid structure, consisting of CF-ABS core layers and outer skins made of ABS, was found to efficiently overcome the stiffness–ductility trade-off. Comparison between the experimental and FEA results demonstrates that Y-orientation with moderate filling densities (60–80 %) has a higher tensile performance. The proposed Taguchi–FEA approach was validate to optimize the mechanical performance of dual-material FDM articles, therefore enables reliable hybrid part design and functionally graded hybrid polymers.
Keywords- Hybrid FDM, ABS–CF-ABS composites, Taguchi optimization, Finite Element Analysis, tensile strength, anisotropy reduction, dual-material 3D printing, mechanical optimization, AMS printing, functionally graded polymers.