ANALYSIS OF THE POSSIBILITIES OF MANUFACTURING FUNCTIONAL ELEMENTS USING THE FFF METHOD

Abstract

The article presents the course and results of research aimed at assessing the strength and practical usability of a furniture hinge additively manufactured from thermoplastic material. The research activities included: development of design assumptions, adoption of target geometry, creation of a 3D-CAD model, preliminary strength analysis in the FEM environment, prototype manufacturing using FFF method with thermoplastic material (pet-g), and conducting tests under conditions similar to real ones. The hinge geometry was based on typical market-available design solutions, while considering the specifics of the adopted manufacturing method. Strength analysis via FEM was conducted on the 3D-CAD model, allowing estimation of stress values and determination of the suitability of the developed geometry for testing on a real model. Subsequently, research models were produced using FFF technology with various infill patterns: linear 30%, hexagonal 30%, linear 60%, hexagonal 60%, and solid 100%. Bench tests were conducted to determine the maximum load-bearing capacity of the hinge under perpendicular loading to the axis and to assess hinge wear under conditions simulating real-life door usage. The results revealed that the hinge with solid infill safely carried a load of 160 kg without damage, while the hinge with hexagonal 30% infill exhibited the lowest load-bearing capacity, failing at 85 kg. To determine the hinge's durability, the clearance at two reference points on the doors was measured.

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