Process Parameters Optimization of Polystyrene Powder Selective Laser Sintering Based on Response Surface Methodology

Ran Yan; Hao Li; Junchao Li; Li Zhu

doi:10.3788/CJL201946.0302015

Chinese Journal of Lasers, Volume. 46, Issue 3, 0302015(2019)

Process Parameters Optimization of Polystyrene Powder Selective Laser Sintering Based on Response Surface Methodology

Ran Yan^1、*, Hao Li², Junchao Li^2、*, and Li Zhu¹

Author Affiliations

¹ Mechanical college, Chongqing University of Technology, Chongqing 400054, China

² College of Materials science and engineering, Chongqing University, Chongqing 310027, China

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Abstract Get PDF(in Chinese)

Figures & Tables(13)

Fig. 1. Tested samples

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Fig. 2. Residual normal probability map

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Fig. 3. Comparison between predicted and actual values

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Fig. 4. Influences of different factors on dimensional deviation rate

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Fig. 5. Relationship of dimensional deviation rate versus laser power and scanning pitch. (a) Response surface diagram; (b) contour map

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Fig. 6. Relationship of dimensional deviation rate versus laser power and layer thickness. (a) Response surface diagram; (b) contour map

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Fig. 7. Relationship of dimensional deviation rate versus scanning pitch and layer thickness. (a) Response surface diagram; (b) contour map

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Fig. 8. Relationship of dimensional deviation rate versus scanning pitch and scanning speed. (a) Response surface diagram; (b) contour map

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Fig. 9. Relationship of dimensional deviation rate versus layer thickness and scanning speed. (a) Response surface diagram; (b) contour map

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Table 1. Experimental factors and levels
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Table 1. Experimental factors and levels
Level Factor
Laser power percentage /% Scan pitch /mm Layer thickness /mm Scan speed /(mm·s^-1)
1 30 0.12 0.15 1800
2 40 0.16 0.20 2000
3 50 0.20 0.25 2200

Table 2. Design parameters and results of experiments

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Table 2. Design parameters and results of experiments

No.	Laser powerpercentage /%	Scanpitch /mm	Layerthickness /mm	Scanspeed /(mm·s^-1)	Error in X /%	Error in Y /%
1	50	0.16	0.2	1800	0.840	0.892
2	50	0.2	0.2	2000	0.733	1.36
3	40	0.12	0.2	2200	0.340	0.608
4	30	0.16	0.2	1800	0.383	1.172
5	40	0.12	0.2	1800	0.913	1.36
6	30	0.16	0.2	2200	0.823	0.976
7	30	0.2	0.2	2000	0.977	1.748
8	40	0.2	0.25	2000	1.217	1.768
9	30	0.16	0.15	2000	0.857	1.528
10	30	0.12	0.2	2000	0.010	0.808
11	40	0.16	0.2	2000	0.473	1.044
12	40	0.2	0.2	2200	0.540	0.8
13	40	0.16	0.2	2000	0.460	1.012
14	50	0.16	0.25	2000	0.903	1.408
15	40	0.16	0.15	2200	0.757	1.024
16	30	0.16	0.25	2000	1.337	1.792
17	40	0.16	0.15	1800	1.270	1.848
18	40	0.12	0.15	2000	0.580	0.924
19	40	0.16	0.25	1800	0.687	1.276
20	40	0.2	0.15	2000	0.617	1.372
21	50	0.16	0.15	2000	0.490	1.036
22	40	0.16	0.2	2000	0.737	1.164
23	50	0.12	0.2	2000	0.300	0.924
24	40	0.12	0.25	2000	0.887	1.224
25	50	0.16	0.2	2200	0.773	0.648
26	40	0.16	0.25	2200	0.690	0.872
27	40	0.2	0.2	1800	0.597	1.136

Table 3. Variance analysis results of optimized model

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Table 3. Variance analysis results of optimized model

Source of variance	Sum of square	Degree of freedom	Mean square error	F	P	Significant
Model	2.46	11	0.22	5.09	0.0028	Y
A-Laser power	0.41	1	0.41	9.26	0.0088
B-Scan pitch	0.20	1	0.20	4.62	0.0495
C-Layer thickness	0.031	1	0.031	0.70	0.4166
D-Scan speed	0.63	1	0.63	14.40	0.0020
AB	0.21	1	0.21	4.88	0.0443
AC	2.916×10^-3	1	2.916×10^-3	0.066	0.8005
BC	2.304×10^-3	1	2.304×10^-3	0.052	0.8222
BD	0.043	1	0.043	0.98	0.3380
CD	0.044	1	0.044	1.00	0.3336
C²	0.58	1	0.58	13.22	0.0027
D²	0.080	1	0.080	1.83	0.1975
Residual	0.62	14	0.044
Lack of fit	0.60	12	0.050	7.82	0.1188	N
Pure error	0.013	2	6.421×10^-3
Total	3.08	25
R²	0.7999	R² adjustment	0.6927	R_SNR	8.562

Table 4. Optimal process plan and model verification

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Table 4. Optimal process plan and model verification

Condition	No.	Laser powerpercentage /%	Scanningpitch /mm	Layerthickness /mm	Scanning speed /(mm·s^-1)	PredictedS /%	RealS /%	Predictederror /%
	1	50	0.12	0.19	2200	0.538
	2	50	0.12	0.19	2199.98	0.540
Optimal	3	50	0.12	0.18	2200	0.541	0.53	5.0
	4	50	0.12	0.20	2200	0.558
	5	50	0.12	0.17	2200	0.568
Verification	6	30	0.2	0.15	2000	1.958	1.837	6.2
	7	40	0.16	0.25	1800	1.436	1.39	3.2

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Ran Yan, Hao Li, Junchao Li, Li Zhu. Process Parameters Optimization of Polystyrene Powder Selective Laser Sintering Based on Response Surface Methodology[J]. Chinese Journal of Lasers, 2019, 46(3): 0302015

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