Varma, R Mahesh and Reddy, N Venkata
(2019)
Studies on Extrusion – Based Additive Manufacturing of Poly-Ether-Ether-Keton (PEEK).
Masters thesis, Indian institute of technology Hyderabad.
Abstract
Additive Manufacturing (AM) is a commonly used process in delivering complex parts with less lead time due to the absence of part specific tooling making it even economical for producing physical models or prototypes. Among all the AM processes, Fused Deposition Modeling (FDM) shares a huge fraction in application perspective for its relatively low equipment cost and ease of use. The most commonly used materials for the FDM process include Acrylonitrile-Butadiene-Styrene (ABS) thermoplastics. Relatively new materials are being added to the list. One such material, which has been identified for its high performance and inert nature is Poly Ether Ether Ketone (PEEK). Its unique properties in delivering high service temperature and biocompatibility enhanced its application in Bio-medical and Aerospace industries. The higher melting temperature of PEEK makes it difficult to fabricate through FDM process. To address the challenge, Screw Extrusion process is employed due to its robust nature in handling materials. The present work deals with processing PEEK material and fabricates components using principles of the AM process. The present study is mainly focused on important parameters like extrusion temperature, road width, standoff distance and print orientation in analyzing the mechanical behavior of PEEK samples. Experimental results suggest that extrusion temperature has a significant role in deciding the material characteristics. Extruding the PEEK above 350 ˚C has degraded the material which resulted in losing materials properties. Also depositions made with lower road width settings has resulted in maximum interbond strength due to the better overlap of each deposition, thereby providing greater cross-section area when subjected to loading. Although experimental studies of tensile samples have been restricted to a single layer depositions, these can provide necessary understanding for multi-layer depositions.
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