Educators Ishould Ibe Iconsidered Ithe Ilearning Istyle Iof Istudents Iso Ithat Ithe Ibest Ipractice Iapproach Ican Ibe Iapplied Iin Ilearning Iactivities. IAs Istudents Iunderstand Itheir Ilearning Istyle, Ithey Iwill Ibe Iable Ito Iintegrate Iit Iinto Itheir Ilearning Iprocess. IKolb ILearning IStyle Iwas Ithe Ilearning Istyle Ithat Iwas Iwidely Iused Ibased Ion Ithe Itheory Iof Ilearning Iexperiences. ITherefore, Ithis Istudy Iaimed Ito Idescribe Iengineering Iand Inon-engineering Istudents’ Ilearning Istyle. IThe Isurvey Iresearch Idesign Iwith Ia Iquantitative Iapproach Iwas Iapplied Iin Ithis Istudy. IA Itotal Iof I300 Irespondents Iwere Iselected Irandomly Ifrom Iall Ifaculties Iin IUniversiti ITun IHussein IOnn IMalaysia. IThe Isurvey Iquestionnaire Iconsisted Iof Itwo Imain Isections Irepresenting ILearning IGoals, ILearning IStyle, Iand ILearning IActivities. IThe Iresult Iexplains Ithat Iboth Iengineering Iand Inon-engineering Istudents Iare Imore Idominant Ito Iadopt Ithe IAccommodator Ilearning Istyle, followed Iby Ithe IConverger Ilearning Istyle, and Ithen IAssimilator Ilearning Istyle and IDiverger Ilearning Istyle. I IIt Iis Iconcluded Ithat Ithe Iengineering Iand Inon-engineering Istudents Iare Imore Iincline Ito Ibe Ia Ikinesthetic Ilearner. IThese Ilearning Ipreferences Iand Ilearning Istyles Iwill Icontribute Ito Itheir Iengagement Iin Ithe Iconcept Iof Ilearning and for educators to plan teaching strategies

Ibrahim, Badaruddin

Junita, Junita

Md Yunos, Jailani

Mohaffyza, Mimi

Rizal, Fahmi

Yee, Mei Heong

UTHM Institutional Repository

Applied Mechanics and Materials VoL660 (2014) pp 8J-88Online uvailable since 20 l1/Oct/3 I crt tutur.:;cienlific.netO Q014) Trans Tech Publications, Switzerlanddo i : I 0. 4 0 2 8 /www. s c ie nt ific. ne t/A M M. 66 0. 8 1Submitted: 23.07.2014Accepted: 07.08.2014Melt Flow Behavior of Metal Filled in Polymer Matrix for FusedDeposition Modeling (FDM) FilamentN.Sa'udet'0, M.lbrahim2'", M. H. l. lbrahim3''1 Department of Manufacturing and Industrial Engineering, Faculty of Mechanical andManufacturing Engineering, UniversitiTunHust";;"?Jil talaysia, 86400 Parit Raja, Batu Pahat,2 Department of Manufacturing and Industrial Engineering, Faculty of Mechanical andManufacturing Engineering, Universiti Tun Hu:ffi:?.?J;; talaysia, 86400 Parit Raja, Batu Pahat,3 Department of Engineering Mechanics, Faculty of Mechanical and Manufacturing Engineering,UniversitiTun Hussein Onn Malaysia, 86400 Parit Raja, Batu Pahat, Johor, Malaysia."nasuha@uthm.edu. my, bmustatfa@uthm.edu. my,'mdhalim@uthm'edu'myKeywords: Fused Deposition Modeling, Melt Flow Behavior, Finite Element Analysis, AcrylonitrileButadiene Styrene, lron.Abstract. This paper presents the melt flow behavior (MFB) of an acrylonitrile butadiene styrene(ABS), Polyproplene (PP). Polylactic Acid (PLA), ABS mix l0% Copper and ABS mix l0o/o Iron inthe simulation. ln this study, the effect MFB of ABS mix with l0% lron and l0%Copper materialwas investigated based on the viscosity, density, thermal conductivity, melting temperature andspecific heat of material properties. The MFB of metal filled in polymer matrix composite(PMc)through the FDM nozzle was investigated using Finite-Element Analysis (ANSYS CFX l2)' Basedon the result obtained, pressure outlet of mix ABS copper and ABS iron in extruder nozzle washigher value compared with others plastic material. The velocity was increased since the nozzlediameter is smaller than the entrance diameter. It can be observed that, the melt flow behavior ofmetal filled in PMC are affected on pressure drop, velocity and the nozzle size at the exit nozzle'INTRODUCTIONNowadays, customer needs and demand on the product customization for low cost product and timesavings have generated a renewed interest in rapid manufacturing (RM) and rapid prototyping (RP)technologies. Among various RP technologies available today, Fused Deposition Modelling (FDM)is one of the technology uses a filament plastic based material. The filament plastic was heated intosemi molten state and deposited on the machine platform for the part fabrication in layer by layerprocess. Normally, the FDM machine involved with either acrylonitrile butadiene styrene (ABS)plastic material U,2,3,4,5,6,7f material. Currently, the most common polymer matrixcomposites(PMC) material used in FDM are ABS-lron[,7,8,9]. ln various research work, someresearcher focuses on the optimal process parameters by taguchi method[l0,ll,l2]' ln order topredict the behavior of new ABS based composite materials during FDM process, it is necessary toinvestigate the flow of the composite rnaterial in the liquefier head [l]. M. Nikzad et al hasmentioned that, the flow behavior of the melts flow channel is affected by the pressure drop,velocity, and the geometrical dimension at the exit. H.S. Ramanath, et al (2007) was investigate themelt flow behavior (MFB) physical properties of poly caprolactone (PCL) such as the meltingtemperature, thermal conductivity, rheology and specific heat. The contribution of the processparameters and material properties data of conductive PMC by ANSYS CFX simulation will give agood information and less error to produce a wire filament by extruder machine' The rapiddeposition of polymer composite (RDPC) with conductive wire filament through the heatedliquefied head in layer by a layer process may offer a great potential in rapid manufacturing andrapid prototyping. The intension of this study is to find out a proper material that will use inAll rights reseryed. No part of contents of this paper m?y be reproduced oriransmitted i1 a1-y.f9p or by any.means without the written permission of TTP'wwwlttp.net. (lD: 103.3i.34.2, Universiti Tun Hussein Onn Malaysia, Parit Rala, L4alaysia-18/1 1/14,03:22:39)Applied Mechanics and Materials Vol.660makerbot replicator machine. This study is focused on the parameter that involved along the meltflow behaviour of plastics filament and combination ABS-I?o/okon and ABS-l0o/o copper in themelt flow nozzle of the makerbot replicator machine by Finite Element Analysis using ANSYS 12software. The parameters that have been investigated are thermal behaviour, pressure drops and thevelocity gradient along melt flow channel. The flow considered as a steady state and there is nochange in flow profile at the time implying a laminar flow. Temperature in the extruder nozzle staysconstant as the working chamber is isolated. Velocity components at the wall of the channel are zeroas the melt is assumed to be adhering to it. Two modes were employ to study the flow behaviour.which is by theoretical modelling and Finite element analysis (FEA). The result of FEA will beanalyze from the melt flow behavior of polymer composites in the FDM simulation to obtain thebest condition to produce a wire filement by the extruder machine.EXPERIMENTALThis study conduct remodel the heated melt flow extruder for fused deposition modeling feedstocksby the simulation ANSYS software. Five types of materials were used in these studies which areABS, PP, PLA, combination of l0o/o Iron-ABS and l0%Copper-ABS material. Two dimension(2D)finite-element analysis of the melts flow behavior will be conducted in Computational FluidDynamic (CFD), which are embedded module in the latest release of the ANSYS Workbench.Material data was selected from the previous research such as HDPE and PP[4], ABS-l0%lron[2]. There are five main properties for each materials should used in the simulation. Theproperties are a density, thermal conductivity, specific heat, viscosity and melting temperature,There are five steps has been done in simulation to complete the ANSYS CFX analyses which aregeometry modeling, meshing, setup, solution and results. The internal geometry modeling ofextruder nozzle shows in Figure I and the CAD data file was import from the solidwork software.; Eflls"rssee#t \:r T85irt Exit V2,.l}- r,pp$Fig. II Boundary conditionTable ll Properties of PPFig. I Extruder nozzle for the FDM headTable I Properties of ABSITEMS ABSSpecific heat O/ksK) 2080Thermal conductivity 1W/mK) 0.177Mass densiW (ke/m3) r 050Initial temoerature of melt (t) 266Viscosity (Pa s) rE4ITEMS PPSpecific heat (J/keK) I 900Thermal conductivify ( W/mK ) 0.r6Mass densitv (ke/mr) 904Initial temperature of melt ( C) 165Viscosity (Pa s) tE7From simulation, the distribution of velocity, pressure and temperature along the melt flow channelwill be analysed for a new wire FDM feedstocks. In the simulation setup, correct inserted data isneeded to avoid error during the simulation and the input data was the material properties andboundary condition setting (refer Figure II). In order to achieve the optimum results, a combinationof tetrahedral, pyramid and prism shaped element is applied in CFX meshing. An assumptions wasI86 Advances in Mechanical, Materials and Manufacturing Engineeringmade in the simulation, where the temperature distribution is similar along the nozzle channel inentrance and exit flow. Table I until Table V shows the different properties of polymer materials.Table III Properties of PLA Table IV Prooerties of ABS-lronITEMS PLASpecific heat (J/ksK) 2n4Thermal conductivity (W/mK) 0.195Mass density (ke/m') 950lnitial temnerature of melt ( C) 230Viscosity (Pa s) 20.8F,6ITEMS ABS-IronSpecific heat (J/keK) I 040Thermal conductivitv (W/mK) 0.258Mass density (ks/mr) t776Initial temoerature of melt ( t) 270Viscosiw (Pa s) 2600of S-Cable V Prooertres t ABITEMS ABS-CopperSpecific heat (J/ksK) l0l0Thermal conductivitv (W/mK) 0.235Mass density (ke/m3) r 660Initial temoerature of melt ( C) 260Viscositv (Pa s) 2700EXPERIMENTAL RESULTExperimental results was coved the pressure drop, velocity and temperaturechannel in the heated nozzle. Five different materials was studied the meltsimulation such as ABS, PP, PLA, ABS- l0% Iron and ABS- I 0% copper.*r1....i4t!jFig.lVdrop*qs* +.*w tnt:.:'n '*13?\Pressurefor PP0.st c0lFig. V Pressure dropfor PLAalong the melt flowflow behavior in theFig. VI Pressuredrop for ABS-lronFig, lll Pressure dropfor ABStgrFig, Vll Pressure dropfor ABS-CopperFig. IX Velocity forABS0 0.ffi1::.,''-.--''-tr''.''.'scu* d6l5Fig. X Velocity PP Fig. XI Velocity PLAApplied Mechanics and Materials Vol.660Pressure Drop along the Melt Flow ChannelIn the simulation, there are three parameters obtained, which are velocity distribution, temperaturedistribution and pressure along the extruder nozzle. Five different materials was used in thesimulation such as ABS, PP, PLA, ABS-10% Iron and ABS-10%o copper The result of pressure dropalong the melt flow channel are shown in Figure III until Figure Vl with different polymer plasticmaterial. From the results obtained, it was found that the properties of mix materials has better thanoriginal materials. It was conclude that, the pressure outlet of mix ABS copper and ABS iron inextruder nozzle was higher value compared with others plastic material. The pressure ABS-10%iron was -l.I27E+05 Pa and ABS-10% copper was -1 .62E+06 Pa. The detail results of pressuredrop are shown in Figure VIII.Velocity along the Melt Flow ChannelThe velocity results obtained in 3D was shows in Figure lX until Figure XIII by CFX. lt wasobserved that an entrance velocity of wire filament is maintained along the flow channel. Whenmelt material flow into the nozzle head, the velocity was increased since the nozzle diameter issmaller than the entrance diameter. The velocity of the melts flow was higher value at the channelcentre than the walls nozzle. Table VI shows the minimum and maximum velocity of differentmaterials in the CFX simulation. A minimum velocity value was 0.0l6lm/s for ABS-l0o/o lron andthe maximum velocity was 0.2231m/s for ABS pure compared with others polymer plasticmaterials. The velocity of non-virgin material ABS iron and ABS copper has less velocity comparedto others.87Tl IEi- o{ IUxterhl verrus \-elocltvI ()O0E-0 I: r{rriE-L}llj r.r(r0E-01A 5 tr{irl.l-ol.6 -,1,,t,t,E-l,l; I 000E-01:o{}frE-crl ,I rj{toE-ol'l Or)0E+0()* {HS-*-!.1)-*- lJli*abs tLott'."+at'i 00pP0locrw ot clltterent matenaMaterial Velocitv (msMinimum MaximumABS 0.0446 0.2231PP 0.0167 0.0836PLA 0.0165 0.082sABS-lron 0.0 r6 r 0.0804ABS-Copper 0.06 | | 0.0804Fig. XIV Types of Materials versus VelocityFie. XIV Types of Materials versus VelociMaterial Temperature(K) Temperature( C)ABS 5.392E+002 266PP 4.381E+002 165PLA 5.031E+002 230ABS-lron 5.4328+002 270ABS-Copper 5.3328+002 260Fig.XIl VelocityABS-lronFig. XIII VelocityABS-CopperTemperature along the Melt Flow ChannelThe temperature distribution from inlet to outlet along the melts flow channel was assume as similarvalue. From the temperature data, it was observed that the ABS-lron had the higher temperature,which is 270 C compared with original ABS approximately. The smaller temperature was PP, whichis 165 C. The melt material temperature was shows in Table Vll.Table VI Vel f diff88 Advances in Mechanical, Materials and Manufacturing EngineeringCONCLUSIONSA combination of ABS mix with iron and copper material has been successfully simulate byANSYS CFX simulation software, From the results obtained in simulation shown that, themaximum pressure of melt flow channel was at the entrance and the velocity profiles showed asmooth flow along the channel and the filaments fully melt at the higher temperatures. In thesimulation, it was reduced the number of experiment trial and to optimize the varietiescompounding material during the PMC wire filament fabrication by extruder machine. Suitablemixing and compounding in the simulation was used as a guidance to fabricate a new filament withmetal filled in polymer matrix. This filament was used in FDM machine to fabricate a conductivepart in alayer by a layer process.References!] C.Y Tang and l.ZLiang, "A study of the melt flow behaviour of ABS/CaCO3 composites," J.of Materials Processing Technology, Vol. 138, pp. 408-410, 2003.[2] M. Nidzad, S. H. Masood, I. sbarski and A. Groth, "A study of melt flow analysis of an ABS-Iron composite in Fused Deposition Modeling process," Tsinghua Sci. and Technol., Vol. 14,No. Sl, pp.29-37,2009.[3] M. Nidzad, S. H. Masood and I. Sbarski, "Thermo Mechanical Properties of a highly filledpofymeric composites for Fused Deposition Modeling," J. of Materials and Design, 32, pp.3448-3456,201 | .[4] J. Tyberg and J. H. Bohn, FDM Systems and local adaptive slicing, "J. of Materials andDesign," 20, pp. 77-82, 1999.[5] A, Bellini and S. G. M. Bertoldi, "Liquefier Dynamics in Fused Deposition," J. ofManufacturing Science and Engineering, 126, pp. 237 -246, 2004.[6] C. Bellehum, L. Li, Q. Sun and P. Gu, "Modeling of bond formation between polymerfilaments in the Fused Deposition Mode.ling Process," J. of Manufacturing Process, 6(2), pp.170-178,2004.[7] S. H. Masood and W. Q. Song, "Development of new metal/polymer materials for rapid toolingusing Fused Deposition Modeling," J. of Materials and Design, 25, pp.587-594,2004.[8] M, Nidzad, S. H. Masood and L Sbarski, "Thermo mechanical properties of a highly filledpolymeric composites for Fused Deposition Modeling," J. of Materials and Design, 32, pp.3448-3456,201t.t9] N. Sa'ude, M. Ibrahim and M. S. Wahab, "Effect of powder loading and binder materials onmechanical properties in Iron-ABS injection molding process," J. of Applied Mechanics andMaterials, 315, pp. 582-586,2013.[0]8.H. Lee, J. Abdullah and Z.A. Khan, "Optimization of rapid prototyping parameters forproduction of flexible ABS object," J. of Materials Processing Technology, pp. 54 - 61,2005.Il]R. Anitha, S. Arunachalam and P. Radhakrishnan, "Critical parameters influencingthe qualityof prototypes in Fused Deposition Modelling," J. of Materials Processing Technology, pp. 385- 388, 2001.[2]A.K. Sood, R.K. Ohdar and S.S. Mahapatra, "Improving dimensional accuracy of FusedDeposition Modelling processed part using grey Taguchi Method," Materials & Design, pp.4243 - 4252,2009.[3]H, S. Ramanath, C. K. Chua and K. F. Leong, "Melt flow behaviour pf Poly-e Caprolactone inFused Deposition Modelling process," J. of Engineering Manufacture, vol. 220(72), pp.254l-255A,2007.[4]M.D. Monzon, N.Diaz, A.N. Benitez et al., "Advantages of Fused Deposition Modelling formaking electrically conductive plastic patterns," International Conference on ManufacturingAutomation, pp, 37 - 43, 2010.

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