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Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle

Huanxiong Xia (Department of Mechanical Engineering, Johns Hopkins University, Baltimore, Maryland, USA)
Jiacai Lu (Department of Mechanical Engineering, Johns Hopkins University, Baltimore, Maryland, USA)
Gretar Tryggvason (Department of Mechanical Engineering, Johns Hopkins University, Baltimore, Maryland, USA)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 28 September 2018

Issue publication date: 15 October 2018

1057

Abstract

Purpose

The purpose of this paper is to continue to describe the development of a comprehensive methodology for fully resolved numerical simulations of fused deposition modeling.

Design/methodology/approach

A front-tracking/finite volume method introduced in Part I to simulate the heat transfer and fluid dynamics of the deposition of a polymer filament on a fixed bed is extended by adding an improved model for the injection nozzle, including the shrinkage of the polymer as it cools down, and accounting for stresses in the solid.

Findings

The accuracy and convergence properties of the new method are tested by grid refinement, and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, the shrinkage and the solid stresses.

Research limitations/implications

The method presented in the paper focuses on modeling the fluid flow, the cooling and solidification and volume changes and residual stresses, using a relatively simple viscoelastic constitutive model. More complex material models, depending, for example, on the evolution of the conformation tensor, are not included.

Practical implications

The ability to carry out fully resolved numerical simulations of the fused deposition process is expected to be critical for the validation of mathematical models for the material behavior, to help explore new deposition strategies and to provide the “ground truth” for the development of reduced-order models.

Originality/value

The paper completes describing the development of the first numerical method for fully resolved simulation of fused filament modeling.

Keywords

Acknowledgements

Part of this research project was conducted using computational resources at the Maryland Advanced Research Computing Center (MARCC).

Citation

Xia, H., Lu, J. and Tryggvason, G. (2018), "Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle", Rapid Prototyping Journal, Vol. 24 No. 6, pp. 973-987. https://doi.org/10.1108/RPJ-11-2017-0233

Publisher

:

Emerald Publishing Limited

Copyright © 2018, Emerald Publishing Limited

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