ABSTRACT
The use of Fused Deposition Modelling (FDM) is a popular Additive Manufacturing (AM) process due to its low cost and the availability of a wide range of materials. However, parts produced using FDM have visible seam-lines and stair-stepping surfaces due to the nature of the extrusion process. Ultrasonic vibration has been applied in conventional machining processes to achieve good surface finish. However, very little research has been carried out to investigate the potential of using this technique for AM to achieve an automated post-processing method. In this study, we developed experimental concepts for an ultrasonic-assisted FDM system and carried out practical experiments using a series of frequencies through an ultrasonic transducer that was attached to the build platform of the desktop FDM printer. In addition, the input parameters evaluated were layer thickness, frequency and fill of surface (air gap) while the output response was surface roughness. Optical examinations through a microscope and a surface roughness metre were used to examine the surface roughness of the samples, and those produced using a 50 kHz of frequency had the best surface finish.
