Modeling of wear performance of 3D⁃printed gears using grey wolf optimization algorithm

doi:10.19491/j.issn.1001-9278.2025.11.015

Abstract

Abstract:

In this study， carbon fiber⁃reinforced nylon gears were fabricated via fused deposition modeling and their wear life was optimized. Utilizing a response surface methodology design， the effects of five key process parameters， including layer height， infill density， raster angle， printing speed， and nozzle temperature， were investigated. The grey wolf optimization （GWO） algorithm was then employed to determine the optimal parameter set for maximizing wear performance. RSM analysis revealed that layer height， infill density， raster angle， and nozzle temperature were significant factors， whereas printing speed had an insignificant effect. Significant interactions were observed between layer height， infill density， raster angle， and temperature. Furthermore， only the second⁃order effects of infill density and raster angle were found to be significant. After 100 iterations， the GWO algorithm predicted an optimal wear life exceeding 40 hours. The corresponding optimal parameters were a layer height of 0.2 mm， an infill density of 89 %， a raster angle of 45 °， a printing speed of 72 mm/s， and a nozzle temperature of 278 ℃. Experimental validation under these conditions yielded a wear life of 41.41 hours， confirming the model's accuracy and the effectiveness of the GWO⁃based optimization approach.

Key words: grey wolf optimization algorithm, response surface model, fused deposition modeling, gear, carbon fiber reinforced nylon, wear performance

CLC Number:

TQ320.66

CHEN Libin, SUN Tengjiao. Modeling of wear performance of 3D⁃printed gears using grey wolf optimization algorithm[J]. China Plastics, 2025, 39(11): 93-99.

Figures/Tables 12

References 19

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性能	数据	性能	数据
密度/g·cm^-3	1.24	断裂伸长率/%	10.61
热变形温度（0.45 MPa）/℃	155	弯曲强度/MPa	140
熔体流动速率（275 ℃/5 kg）/g·（10 min）^-1	11.46	弯曲模量/MPa	4 363
拉伸强度/MPa	140	悬臂梁缺口冲击强度/kJ·m^-2	18.67

性能	数据	性能	数据
密度/g·cm^-3	1.24	断裂伸长率/%	10.61
热变形温度（0.45 MPa）/℃	155	弯曲强度/MPa	140
熔体流动速率（275 ℃/5 kg）/g·（10 min）^-1	11.46	弯曲模量/MPa	4 363
拉伸强度/MPa	140	悬臂梁缺口冲击强度/kJ·m^-2	18.67

因素	低水平	中水平	高水平
层高（A）/mm	0.2	0.3	0.4
填充密度（B）/%	70	80	90
栅格角度（C）/°	0	45	90
打印速度（D）/mm·s^-1	40	60	80
喷嘴温度（E）/℃	260	280	300

因素	低水平	中水平	高水平
层高（A）/mm	0.2	0.3	0.4
填充密度（B）/%	70	80	90
栅格角度（C）/°	0	45	90
打印速度（D）/mm·s^-1	40	60	80
喷嘴温度（E）/℃	260	280	300

试验序号	层高（A）/mm	填充密度（B）/%	栅格角度（C）/°	打印速度（D）/mm·s^-1	喷嘴温度（E）/℃	磨损寿命/h
1	0.30	80.00	45.00	80.00	300.00	37.82
2	0.30	70.00	45.00	40.00	280.00	11.25
3	0.30	80.00	45.00	80.00	260.00	21.4
4	0.40	90.00	45.00	60.00	280.00	9.92
5	0.20	80.00	0.00	60.00	280.00	29.77
6	0.30	90.00	45.00	60.00	260.00	16.84
7	0.20	90.00	45.00	60.00	280.00	22.31
8	0.30	80.00	90.00	60.00	300.00	5.67
9	0.40	70.00	45.00	60.00	280.00	36.48
10	0.30	70.00	45.00	80.00	280.00	33.52
11	0.30	80.00	45.00	60.00	280.00	30.61
12	0.30	70.00	45.00	60.00	260.00	14.26
13	0.30	80.00	90.00	80.00	280.00	9.88
14	0.30	80.00	45.00	60.00	280.00	17.45
15	0.30	90.00	90.00	60.00	280.00	11.07
16	0.30	70.00	45.00	60.00	300.00	3.98
17	0.30	80.00	0.00	60.00	260.00	23.53
18	0.40	80.00	45.00	80.00	280.00	13.41
19	0.30	90.00	45.00	80.00	280.00	5.32
20	0.40	80.00	45.00	60.00	300.00	12.22
21	0.30	80.00	90.00	60.00	260.00	18.01
22	0.30	80.00	45.00	40.00	260.00	8.44
23	0.30	80.00	45.00	40.00	300.00	25.58
24	0.20	80.00	45.00	60.00	300.00	39.77
25	0.30	90.00	0.00	60.00	280.00	22.99
26	0.40	80.00	90.00	60.00	280.00	13.59
27	0.30	90.00	45.00	60.00	300.00	31.06
28	0.40	80.00	0.00	60.00	280.00	11.35
29	0.30	90.00	45.00	40.00	280.00	26.77
30	0.30	70.00	0.00	60.00	280.00	7.14
31	0.20	80.00	45.00	80.00	280.00	34.5
32	0.30	80.00	0.00	60.00	300.00	19.34
33	0.40	80.00	45.00	60.00	260.00	9.9
34	0.40	80.00	45.00	40.00	280.00	15.63
35	0.20	80.00	45.00	60.00	260.00	38.12
36	0.30	80.00	0.00	80.00	280.00	12.19
37	0.30	80.00	0.00	40.00	280.00	7.98
38	0.30	70.00	90.00	60.00	280.00	19.83
39	0.30	80.00	45.00	60.00	280.00	24.47
40	0.20	80.00	45.00	40.00	280.00	33.41
41	0.30	80.00	90.00	40.00	280.00	6.37
42	0.20	80.00	90.00	60.00	280.00	28.09
43	0.20	70.00	45.00	60.00	280.00	35.72