Thermal Analysis and Parameter Optimization of the Ironing Process for FDM-Printed PLA and ABS Parts

The surface roughness of fused deposition modeling (FDM) parts severely limits their applications. Ironing, as an effective method to enhance surface quality, exhibits unclear interactions among its process parameters and lacks defined optimal process windows for different materials. To address this, this study employs a simulation to reveal the influence of ironing speed on the temperature field. Combining single-factor experiments with response surface methodology, predictive models for the surface roughness of PLA and ABS are established. Results indicate significant parameter interactions: PLA roughness is primarily governed by the interaction between ironing speed and ironing flow, while ABS roughness is co-influenced by the main effects of all three parameters (ironing speed, ironing flow, and ironing line spacing) as well as the interactions between speed and flow, and speed and line spacing. After optimization, the optimal surface roughness Ra values for PLA and ABS parts reached 0.852 μm and 1.014 μm, respectively. This study clarifies the dependence of ironing process effectiveness on material properties at the experimental optimization level, providing a theoretical basis for precise control of the FDM ironing process.