Hybrid estimation of surface roughness distribution in FDM parts using analytical modeling and empirical investigation

In this study, surface roughness of the ABSplus part fabricated by fused deposition modeling (FDM) is improved by using the proposed methodology based on analytical modeling, where effective process parameters are optimized in the process planning stage. A new hybrid model is proposed for the analytical estimation of the surface roughness based on experimental investigation and the best performance results of the most cited analytical models. A specific test part capable of evaluating the surface roughness distribution for all surface build angles is designed and fabricated. The robustness of the recommended model is studied, and its performance is compared to other analytical models, where the results demonstrate a significant advancement in surface roughness estimation. The proposed model is validated comprehensively for other parts with various materials, process parameters, machines, and shapes to represent the general application of the hybrid model. Consequently, the summary of the evaluation confirms the capability of more fitted responses in the newly proposed model.