Development of a flow-based predictive model for the coalescence of fused deposition modeling filaments

2014 ◽  
Author(s):  
◽  
Brian Graybill
Keyword(s):  
Bond Length ◽  
Fused Deposition Modeling ◽  
Predictive Accuracy ◽  
Weight Ratio ◽  
High Strength ◽  
Accurate Prediction ◽  
Bond Lengths ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
End Use

[ACCESS RESTRICTED TO THE UNIVERSITY OF MISSOURI AT AUTHOR'S REQUEST.] As rapid prototyping processes continue to be developed, there is increasing use of such processes for the production of end-use parts. Fused deposition modeling (FDM) is a particularly favorable method for fabricating end-use parts because of the wide selection of materials available for the process such as Ultem 9085, prized by the aerospace industry for its high strength-to-weight ratio. To confidently employ FDM parts in service requires a thorough understanding of their behavior under expected loading conditions and the ability to predict their success for failure in a particular application. The strength of an FDM part is derived from the amount of bonding that occurs between the polymer filaments as they are deposited. Thus, an accurate prediction of this bond length should lead naturally to an accurate prediction of part strength. Models simulating the heat transfer and coalescence experienced by a pair of adjacent filaments are developed and presented. The models are executed across a range of build parameters to help determine flexibility, and provide a value for the predicted bond length. To validate the models, FDM parts are built from Ultem 9085, cross sectioned, and imaged. The images allow measurements of actual bond lengths to be obtained. The measured bond lengths are compared to the predicted bond lengths. Only a select number of bond lengths measurements are obtained because of variations in microstructure corresponding to various build parameters. A predictive accuracy of 95 % is desired, but the model is unable to achieve it due to estimates of critical data that is unavailable and the variability inherent in the FDM process. However, the simulations provide a significant foundation for future modeling efforts aimed at providing a model capable of predicting bond lengths, and therefore strengths, of FDM parts.

Enhancing the mechanical properties of SCF/PEEK composites in FDM via process-parameter optimization

2021 ◽  
pp. 095400832110036
Author(s):  
Bin Hu ◽  
Zehua Xing ◽  
Weidong Wu ◽  
Xiaojun Zhang ◽  
Huamin Zhou ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Low Cost ◽  
Weight Ratio ◽  
High Strength ◽  
Processing Parameters ◽  
High Viscosity ◽  
Polymer Composite Material ◽  
Fused Deposition ◽  
Deposition Modeling

Short-carbon-fiber (SCF)–reinforced poly-ether-ether-ketone (PEEK) is a promising polymer composite material with good biocompatibility, a high strength-to-weight ratio, and low friction properties. In artificial-bone fabrication and other applications with more flexible fabrication demands, fused-deposition modeling (FDM) technology enables the rapid and low-cost fabrication of SCF/PEEK parts with sophisticated structures. Owing to the high viscosity of melting PEEK composites, great challenges, associated with the poor internal interface, need to be overcome before enhanced mechanical properties can be obtained. In this study, key processing parameters and various SCF amounts were studied to investigate their effects on the mechanical properties of PEEK composites. It was revealed that the existence of voids and gaps between the SCF and PEEK led to a decrease in the strength of the composite systems. The FDM processing parameters were tuned to eliminate these defects in the PEEK composites. The tensile strength of the 2% SCF/PEEK sample reached 96.4 MPa, which is comparable to that of PEEK parts prepared by injection molding. Meanwhile, its elastic modulus reached 2.6 GPa, which is 169% higher than that of the bare PEEK sample.

scholarly journals Development of predictive models for the coalescence of fused deposition modeling fibers

2017 ◽  
Author(s):  
◽  
Quan Hong Nguyen
Keyword(s):  
Bond Strength ◽  
Bond Length ◽  
Predictive Models ◽  
Fused Deposition Modeling ◽  
Sintering Process ◽  
Manufacturing Method ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
End Use ◽  
Sintering Processes

Fused deposition modeling (FDM) is the prominent manufacturing method for fabricating end-use parts due to the ability to build complicated structures. In order to be used confidentially in the industry requires a thorough understanding of mechanical behavior of FDM parts under working conditions. The strength of FDM parts is negatively influenced by the insufficient bond strength achieved between fibers, the weakest links in the FDM parts are the weak inter-layer bonds and intra-layer bonds. The aim of this study is to create models that can accurately predict bond length and bond strength between fibers. Analytical equations describing the sintering processes and heat transfer between FDM fibers and surrounding environment are developed and presented. By comparing the predicted value to the actual bond length, the models are found to be moderately accurate. To validate the relation between bond length and bond strength and also determine the process parameters that affect the bond strength, design of experiments (DOE) and analysis of variance (ANOVA) were applied. The result showed that the extrusion temperature to be statistically significant. Further research is recommended to take in to account more factors that could affect the cooling and sintering process that will help improve the precision of predictive models.

Mechanical performance of honeycomb sandwich structures built by FDM printing technique

2021 ◽  
pp. 089270572199789
Author(s):  
S Gohar ◽  
G Hussain ◽  
A Ali ◽  
H Ahmad
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Sandwich Structures ◽  
Weight Ratio ◽  
High Strength ◽  
Core Material ◽  
Interfacial Bond Strength ◽  
Fused Deposition ◽  
Competitive Prices ◽  
Composite Face

Honey Comb Sandwich Structures (HCSS) have numerous applications in aerospace, automobile, and satellite industry because of their properties like high strength to weight ratio, stiffness and impact strength. Fused Deposition Modeling (FDM) is a process which, through its flexibility, simple processing, short manufacturing time, competitive prices and freedom of design, has an ability to enhance the functionality of HCSS. This paper investigates the mechanical behavior (i.e. flexural, edgewise compression and Interfacial bond strength) of FDM-built HCSS. The influence of face/core material was examined by manufacturing four types of specimens namely ABS core with Composite (PLA + 15% carbon fibers) face sheets, ABS core with PLA face sheets, TPU core with composite face sheets and TPU core with PLA face sheets. To measure the effect of face sheets geometry, raster layup was varied at 0°/90° and 45°/−45°. The mechanical characterization revealed that an optimum combination of materials is ABS core with composite face sheets having raster layup of 0°/90°. This study indicates that HCSS with complex lamination schemes and adequate mechanical properties could be manufactured using FDM which may widen the applications of FDM on an industrial scale.

scholarly journals Comparison Of FEA Simulations And Experimental Results For As-Built Additively Manufactured Dogbone Specimens

2021 ◽  
Author(s):  
Prathamesh Baikerikar ◽  
Cameron J Turner
Keyword(s):  
Fused Deposition Modeling ◽  
Experimental Tests ◽  
Continuum Models ◽  
Element Analysis ◽  
Fused Deposition ◽  
Accuracy And Precision ◽  
Structure Strength ◽  
Deposition Modeling ◽  
End Use ◽  
Strength And Stiffness

Abstract Parts built using Fused Deposition Modeling (FDM – an additive manufacturing technology) differ from their design model in terms of their microstructure and material properties. These differences lead to a certain amount of ambiguity regarding the structure, strength and stiffness of the final FDM part. Increasing use of FDM parts as end use products, necessitates accurate simulations and analyses during part design. However, analysis methods such as Finite Element Analysis, are used for analysis of continuum models, and may not accurately represent the non-continuous non-linear FDM parts. Therefore, it is necessary to determine the accuracy and precision of FEA for FDM parts. The goal of this study is to compare FEA simulations of the as-built geometries with the experimental tests of actual FDM parts. Dogbone geometries that include different infill patterns are tested under tensile loading and later simulated using FEA. This study found that FEA results are not always an accurate or reliable means of predicting FDM part behaviors.

Investigating the Impacts of Heterogeneous Infills on Structural Strength of 3D Printed Parts

2019 ◽  
Vol 799 ◽  
pp. 276-281
Author(s):  
Ramisha Sajjad ◽  
Sajid Ullah Butt ◽  
Khalid Mahmood ◽  
Hasan Aftab Saeed
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Weight Ratio ◽  
3D Cad ◽  
Fused Deposition ◽  
Material Usage ◽  
Rectangular Pattern ◽  
Build Time ◽  
Deposition Modeling

Additive Manufacturing is a manufacturing process based on layers for making three dimensional scaled physical parts directly from 3D CAD data. Fused Deposition Modeling (FDM) is widely used technology that provides functional prototypes in various thermoplastics. In additive manufacturing, filling patterns are of two types; External and Internal filling patterns. Multiple patterns are developed for both filling categories. In this work, a heterogeneous infill strategy is used by choosing developed patterns in order to improve strength to weight ratio, material usage and build time for parts. A rectilinear pattern combination with triangular and rectangular pattern has been chosen for 3D printing. The tensile testing is performed on the printed specimens to calculate the strength to weight ratio. By comparing the obtained results, a strategy based on maximum strength to weight ratio, minimum material usage and reduced build time is recommended for FDM technology.

Design and verification of enhanced CFRTPCs fabrication technique using fused deposition modeling

2020 ◽  
pp. 089270572094191
Author(s):  
Ali Bin Naveed ◽  
Shahid Ikramullah Butt ◽  
Aamir Mubashar ◽  
Fausz Naeem Chaudhry ◽  
Najam ul Qadir ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Control Method ◽  
Volume Fraction ◽  
Research Work ◽  
High Strength ◽  
Thermoplastic Composites ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Industrial Level

Research shows that mechanical properties of parts produced using fused deposition modeling (FDM) are inferior when compared to parts produced using conventional techniques such as injection molding. Efforts have been made in recent years to improve mechanical properties by reinforcing the parts with high strength fibers. This has been achieved by either modifying FDM setups to extrude fibers with thermoplastics and fabricate continuous fiber reinforced thermoplastic composites (CFRTPCs) or employing manual techniques subsequent to part production. Existing CFRTPCs fabrication procedures have limitations of fiber exposure to environment, no direct control method for volume fraction, and poor surface finish. This research work is focused on improving the process of producing CFRTPCs by addressing these limitations using a dual extruder FDM setup. The process developed was tested for its feasibility using Kevlar fiber as reinforcement for commercially available ABS, PLA, PLA-C, and PLA-Cu thermoplastic fibers. Taguchi L16 orthogonal array was used to design experiments, while tensile and flexural testing was performed to determine mechanical properties achieved. Tensile strength was improved up to 3 times the baseline value of thermoplastics, while flexural strength was improved up to 1.6 times. This technique can further the goal of developing CFRTPCs, on industrial level, using FDM with better control over volume fraction and fiber layup.

scholarly journals Mechanical and Thermal Behavior of Ultem® 9085 Fabricated by Fused-Deposition Modeling

2020 ◽  
Vol 10 (9) ◽  
pp. 3170 ◽  
Author(s):  
Elisa Padovano ◽  
Marco Galfione ◽  
Paolo Concialdi ◽  
Gianni Lucco ◽  
Claudio Badini
Keyword(s):  
High Performance ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Mechanical And Thermal Properties ◽  
Fused Deposition ◽  
Wide Range ◽  
Deposition Modeling ◽  
End Use ◽  
Flexural Tests ◽  
Oxidative Behavior

Fused-deposition modeling (FDM) is an additive manufacturing technique which is widely used for the fabrication of polymeric end-use products in addition to the development of prototypes. Nowadays, there is an increasing interest in the scientific and industrial communities for new materials showing high performance, which can be used in a wide range of applications. Ultem 9085 is a thermoplastic material that can be processed by FDM; it recently emerged thanks to such good properties as excellent flame retardancy, low smoke generation, and good mechanical performance. A deep knowledge of this material is therefore necessary to confirm its potential use in different fields. The aim of this paper is the investigation of the mechanical and thermal properties of Ultem 9085. Tensile strength and three-point flexural tests were performed on samples with XY, XZ, and ZX building orientations. Moreover, the influence of different ageing treatments performed by varying the maximum reached temperature and relative humidity on the mechanical behavior of Ultem 9085 was then investigated. The thermal and thermo-oxidative behavior of this material was also determined through thermal-gravimetric analyses.

scholarly journals Comparison of As-Built FEA Simulations and Experimental Results for Additively Manufactured Dogbone Geometries

2017 ◽  
Author(s):  
Prathamesh J. Baikerikar ◽  
Cameron J. Turner
Keyword(s):  
Material Properties ◽  
Fused Deposition Modeling ◽  
Experimental Tests ◽  
Tensile Loading ◽  
3D Models ◽  
Element Analysis ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
End Use ◽  
Strength And Stiffness

Fused Deposition Modeling (FDM - a technology of additive manufacturing) parts entail a certain amount of ambiguity in terms of its material properties and microstructure due to its manufacturing technique. Therefore, an FDM part differs from its design model in terms of strength and stiffness. With an increasing amount of FDM parts being used as end use products, it is necessary to simulate and analyze them. Due to the differences in microstructure and material properties of FDM parts, it is necessary to determine the accuracy of analysis methods like Finite Element Analysis (FEA) while analyzing the non-continuous, non-linear FDM parts. The goal of this study is to compare FEA simulations of the as-built geometries with the experimental tests of actual FDM parts. A dogbone geometry with different infill patterns is tested under tensile loading. Further, as-built 3D models are simulated using FEA and the stress results are compared with experimental data. This study found that FEA results are not always an accurate or reliable means of predicting FDM part behaviors.

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