Process Simulation for Screw Extrusion Additive Manufacturing of Plastic Parts

2021 ◽  
pp. 156-169
Author(s):  
Johannes Albers ◽  
Ulf Hillemann ◽  
Andreas Retzlaff ◽  
André Hürkamp ◽  
Klaus Dröder
Keyword(s):  
Additive Manufacturing ◽  
Process Simulation ◽  
Screw Extrusion ◽  
Plastic Parts

scholarly journals Design for Additive Manufacturing and for Machining in the Automotive Field

2021 ◽  
Vol 11 (16) ◽  
pp. 7559
Author(s):  
Elena Bassoli ◽  
Silvio Defanti ◽  
Emanuele Tognoli ◽  
Nicolò Vincenzi ◽  
Lorenzo Degli Esposti
Keyword(s):  
Additive Manufacturing ◽  
Process Simulation ◽  
Automotive Application ◽  
Powder Bed Fusion ◽  
Design For Additive Manufacturing ◽  
Good Correspondence ◽  
Powder Bed ◽  
Aluminum Component ◽  
Machining Operations ◽  
First Time

High cost, unpredictable defects and out-of-tolerance rejections in final parts are preventing the complete deployment of Laser-based Powder Bed Fusion (LPBF) on an industrial scale. Repeatability, speed and right-first-time manufacturing require synergistic design approaches. In addition, post-build finishing operations of LPBF parts are the object of increasing attention to avoid the risk of bottlenecks in the machining step. An aluminum component for automotive application was redesigned through topology optimization and Design for Additive Manufacturing. Simulation of the build process allowed to choose the orientation and the support location for potential lowest deformation and residual stresses. Design for Finishing was adopted in order to facilitate the machining operations after additive construction. The optical dimensional check proved a good correspondence with the tolerances predicted by process simulation and confirmed part acceptability. A cost and time comparison versus CNC alone attested to the convenience of LPBF unless single parts had to be produced.

vELECTROPLATING POLYMER BASED ADDITIVE MANUFACTURED PARTS FOR ENHANCED STRUCTURAL PERFORMANCE

2021 ◽  
Author(s):  
WARUNA SENEVIRATNE, ◽  
JOHN TOMBLIN ◽  
BRANDON SAATHOFF
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Thickness Variation ◽  
Manufacturing Processes ◽  
Fused Deposition ◽  
Aerospace Applications ◽  
Electroplated Coating ◽  
Traditional Manufacturing ◽  
Plastic Parts ◽  
Subtractive Machining

Additive manufacturing has been adopted in many aerospace and defense applications to reduce weight and buy-to-fly ratios of low-volume high- complexity parts. Polymer-based additive manufacturing processes such as Fused Deposition Modeling (FDM) has enabled aerospace manufactures to improve the structural efficiency of parts through generative design or topology optimization. This level of design freedom did not exist in the past due to limitations associated with traditional manufacturing processes such as subtractive machining. Improvements in the material and the maturation of the FDM process has led to the production of many non-structural flightworthy parts used in aircraft today. Polymer-based additive manufacturing can be further leveraged in aerospace applications with the addition of electroplated coatings that act as reinforcement. While many of the commonly known electroplated coating applications involve enhancing the part appearance, electroplated coatings can also improve the strength, stiffness, and durability of plastic parts. Depending on the use case, the thickness of the metallic plating material (combination of copper and nickel) can be tailored to achieve the desired composite properties (metal and polymer). In this research, the tensile and flexural mechanical properties were assessed for Ultem™ 9085 FDM printed specimens and compared to specimens with metallic coating thicknesses of approximately 75-μm, 150-μm, and 300-μm. Non- destructive inspections using x-ray computed tomography were performed prior to mechanical testing to assess the electroplated coating thickness variation and overall quality.

scholarly journals Embedding Sensors in FDM Plastic Parts During Additive Manufacturing

2016 ◽  
pp. 205-214 ◽  
Author(s):  
Lexey R. Sbriglia ◽  
Andrew M. Baker ◽  
James M. Thompson ◽  
Robert V. Morgan ◽  
Adam J. Wachtor ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Plastic Parts

scholarly journals Selective Laser Melting process simulation of open lattice cellular materials

2018 ◽  
Vol 188 ◽  
pp. 03019
Author(s):  
George Lampeas
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Simulation ◽  
Melting Process ◽  
Element Model ◽  
Cellular Materials ◽  
Laser Melting ◽  
Simulation Methodology ◽  
Efficient Simulation ◽  
Present Simulation

In the present paper an efficient simulation of an Additive Manufacturing process is presented. The analysis is aiming to quantify the relations between process parameters and material characteristics. The methodology is demonstrated in the fabrication of an open-lattice Body- Centred-Cubic (BCC) cellular core, produced by means of the Additive Manufacturing Selective Laser Melting method. The results of the developed finite element model are compared to experimental results demonstrating a successful validation of the simulation methodology. The results of the present simulation can be used as input for the prediction of the mechanical properties of the cellular materials under investigation.

Numerical Prediction of Residual Deformation and Failure for Powder Bed Fusion Additive Manufacturing of Metal Parts

2020 ◽  
Vol 36 (5) ◽  
pp. 623-636
Author(s):  
D.D. Lyu ◽  
W. Hu ◽  
B. Ren ◽  
X.F. Pan ◽  
C. T. Wu
Keyword(s):  
Additive Manufacturing ◽  
Process Simulation ◽  
Residual Deformation ◽  
Numerical Approach ◽  
Small Scale ◽  
Powder Bed Fusion ◽  
Failure Characteristics ◽  
Deformation And Failure ◽  
Powder Bed ◽  
Inherent Strain Method

ABSTRACTResidual deformation and failure are two critical issues in powder bed fusion (PBF) additive manufacturing (AM) of metal products. Residual deformation caused by the non-uniform residual stress distribution dramatically affects the quality of AM product and can result in catastrophic failure in operation. Therefore, the development of an effective numerical approach to predict residual deformation and failure characteristics of AM product is always a major concern in industrial applications.In this paper, a numerical approach in predicting residual distortion, stress and failure in AM products is presented. The conventional inherent strain method used in welding process is modified to consider the specific characteristic of AM process, such as the influences of reheating and scanning pattern. This approach consists of three simulation steps including a detailed process simulation in small-scale, a onetime static mechanical finite element analysis in part-scale, and a material failure analysis. First, the inherent strains are calculated from a thermo-mechanical process simulation in small-scale, which considers AM process parameters, such as laser power, scanning speed and path. The physical state in deposited materials including powder, liquid and solid states are taken into account in the simulation by specifying the solidus and liquidus temperature and corresponding material properties. Then the inherent strains are applied layer by layer to the part-scale simulation, where the residual distortion and stress can be predicted efficiently. Finally, a Lagrange particle method is utilized to study the failure characteristics of AM products. Numerical examples are studied to investigate the effectiveness and applicability of present approach.

Produktivitätssteigerung durch Hybridisierung im 3D-Druck/Process development for the automated production of plastic parts with integrated functional components. Increased productivity through hybridization in 3D printing

2020 ◽  
Vol 110 (07-08) ◽  
pp. 521-525
Author(s):  
Michael Baranowski ◽  
Markus Netzer ◽  
Sven Coutandin ◽  
Jürgen Fleischer
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Manufacturing Process ◽  
Process Development ◽  
Flexible Production ◽  
Additive Fertigung ◽  
Automated Production ◽  
Individualized Production ◽  
Plastic Parts ◽  
Functional Components

Die additive Fertigung erlaubt eine standortunabhängige sowie de facto individualisierte Produktion von Bauteilen mit nahezu beliebiger Komplexität. Für die flexible Herstellung von hochfunktionalen Hybridbauteilen fehlt es allerdings an entsprechenden Maschinenkonzepten sowie Automatisierungslösungen. Durch ein hier vorgestelltes Anlagenkonzept sollen Funktionskomponenten in den additiven Herstellungsprozess integriert und neue Möglichkeiten der Bauteilhybridisierung erforscht werden.   Additive manufacturing allows a location-independent and de facto individualized production of components of almost any complexity. However, there is a need for appropriate machine concepts and automation solutions for the flexible production of highly functional hybrid components. A plant concept presented here is intended to integrate functional components into the additive manufacturing process and to explore new possibilities for component hybridization.

Design for Injection Molding: Using Dimensional Analysis to Assess Fillability

1994 ◽  
Author(s):  
Douglas C. Mehl ◽  
Kurt A. Beiter ◽  
Kos Ishii
Keyword(s):  
Dimensional Analysis ◽  
Process Simulation ◽  
Design Guidelines ◽  
Experimental Program ◽  
Flow Length ◽  
Numerical Process ◽  
Injection Molded ◽  
Plastic Parts ◽  
Injection Molded Plastic

Abstract This paper addresses the determination of wall thicknesses and gating schemes in the preliminary design of injection-molded plastic parts. Today, most of the existing design guidelines come in the form of experience-based qualitative rules. If the designers already have a detailed geometry of the part, the numerical process simulation program provides another form of design aid. There exists a huge gap between these two types of design aids; the experience-based guidelines are often too vague, while the process simulation programs come too late to impact preliminary part design. To fill this gap, this paper develops physics-based guidelines that utilize dimensional analysis techniques. Experiments and simulation studies can deduce non-dimensional relationships between flow length, thickness, material, and process parameters. The guidelines will aid plastic component designers in determining wall-thickness, gating schemes, and in selecting the material in the preliminary stages of part design. This paper describes the formulation of the non-dimensional charts for fillability assessment, and explains the use of these charts in part design. We further outline an ongoing experimental program to validate and refine our formulation.

scholarly journals Curved Layer Fused Deposition Modeling in Conductive Polymer Additive Manufacturing

2011 ◽  
Vol 199-200 ◽  
pp. 1984-1987 ◽  
Author(s):  
Olaf Diegel ◽  
Sarat Singamneni ◽  
Ben Huang ◽  
Ian Gibson
Keyword(s):  
Additive Manufacturing ◽  
Printed Circuit Boards ◽  
Fused Deposition Modeling ◽  
Conductive Polymer ◽  
Fused Deposition ◽  
National University ◽  
Deposition Modeling ◽  
Plastic Components ◽  
Manufacturing Technologies ◽  
Plastic Parts

This paper describes a curved-layer additive manufacturing technology that has the potential to print plastic components with integral conductive polymer electronic circuits. Researchers at AUT University in New Zealand and the National University of Singapore have developed a novel Fused Deposition Modeling (FDM) process in which the layers of material that make up the part are deposited as curved layers instead of the conventional flat layers. This technology opens up possibilities of building curved plastic parts that have conductive electronic tracks and components printed as an integral part of the plastic component, thereby eliminating printed circuit boards and wiring. It is not possible to do this with existing flat-layer additive manufacturing technologies as the continuity of a circuit could be interrupted between the layers. With curved-layer fused deposition modeling (CLFDM) this problem is removed as continuous filaments in 3 dimensions can be produced, allowing for continuous conductive circuits.

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