Optimizing Surface Finish in FDM-Printed Polycarbonate Spur Gears through Abrasive Flow Finishing: Insights from Physics and Material Science Perspectives

Abstract In recent times, the usage of polymers has experienced notable growth across diverse manufacturing sectors. Polymeric gears, integral to automation, material handling systems, toys, and household appliances, have become ubiquitous. Although additive manufacturing techniques, especially Three-Dimensional (3D) printing, offer versatile applications, they grapple with challenges, notably poor surface finishing attributed to layer accumulation. This work explores the field of abrasive flow machining (AFM) in experimental settings using FDM-printed polymeric gears. The AFM medium concoction involves coal ash powder as the foundational material, EDM oil as the carrier fluid, and the infusion of glycerin as additives. Rigorous investigations were undertaken to pinpoint the optimal viscosity of the AFM medium and refine process parameters with a central focus on enhancing surface quality. A Taguchi L9 Design of Experiment (DOE) was meticulously crafted for parameter optimization using the Minitab statistical software. The investigation established a functional relationship between the output parameter (surface roughness) and key input variables (layer thickness, abrasive percentage, abrasive mesh size, and finishing time). The maximum level of AFM media optimization was attained at 33% abrasive concentration, 220 abrasive mesh size, and 60% liquid synthesizer. Additionally, the results of the investigation showed that a media viscosity of 0.50 Pa-sec, layer thickness of 0.1, and culminating time of 45 min were the optimal values for the most % improvement in surface roughness. The initial surface roughness underwent a profound reduction from 12.30 μ m to 0.30 μ m, marking an exceptional improvement of 97.56%. This inquiry contributes significant insights into the refinement of AFM parameters for elevating the surface finish of FDM-printed polymeric gears, promising enhanced performance across diverse applications.