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Rapid residual stress prediction and feedback control during fused deposition modeling of PLA

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Abstract

Residual stress plays a key role in the mechanical properties and geometry stability of the printing parts during Fused Deposition Modeling (FDM). Being the representative thermoplastic in this type of manufacturing process, the process parameters of polylactic acid (PLA) in FDM have a significant impact on the residual stress of PLA. According to the multiphysics model established, the residual stress decreases with increasing layer thickness, printing speed or platform temperature. Because such traditional finite element analysis takes a long time to calculate the stress, a back propagation (BP) neural network model is established for rapid stress prediction under different processing parameters during FDM. Only 0.56 s is required with such model during each run and the prediction error is controlled in 10%. A close loop system is simulated with temperature modification to mimic an ideal real-time feedback. Meanwhile, by off-line adjusting the FDM process parameters, the residual stress along X direction can be controlled to a certain range from experiments. An intelligent additive manufacturing system can be envisaged with the possibility of stress state modification at any time and any position in the future.

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Funding

This work was supported by Shanghai Sailing Program (No.18YF1408400) and National Key R&D Program of China (No. 2018YFB2000300).

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Authors and Affiliations

  1. School of Mechatronic & Automation Engineering, Shanghai University, Shanghai, 200444, China

    Qi Zhu, Kang Yu, Hanqiao Li & Dawei Tu

  2. Corporate Technology, Siemens Ltd., Beijing, 100102, China

    Qingqing Zhang

Authors
  1. Qi Zhu
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  2. Kang Yu
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  3. Hanqiao Li
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  4. Qingqing Zhang
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  5. Dawei Tu
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Contributions

Qi Zhu contributes to the conceptualization, methodology and resources. Kang Yu contributes in simulation and prepares the original draft. Hanqiao Li helps for experimental investigation. Qingqing Zhang contributes to the reviewing and editing. Dawei Tu helps for data curation and validation. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Qi Zhu.

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Zhu, Q., Yu, K., Li, H. et al. Rapid residual stress prediction and feedback control during fused deposition modeling of PLA. Int J Adv Manuf Technol 118, 3229–3240 (2022). https://doi.org/10.1007/s00170-021-08158-0

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  • DOI: https://doi.org/10.1007/s00170-021-08158-0

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