Mathematical modelling of surface roughness for vapour processing of ABS parts fabricated with fused deposition modelling

Fused deposition modelling (FDM) has number of applications in the field of metal casting but the poor surface finish acts as major obstruction against rapid investment casting of the replicas prepared by this process. The vapour smoothing (VS) has proved to be promising technique as fine details of parts are preserved due to absence of tool-work piece contact and mechanical force. In the present study, the outcome of Taguchi and ANOVA analysis has been used to develop a mathematical model for average surface roughness of vapour treated parts prepared by FDM. The relationship between six input parameters, two of FDM and four of VS has been derived using Buckingham's Pi theorem. The study explored the effect of smoothing time and number of cycles on surface roughness and as confirmed by statistical analysis. The model gives output in form of percentage change in surface roughness as a function of smoothing time and number of cycles where final roughness of vapour exposed FDM parts can be predicted.