Prediction of part distortion in Fused Deposition Modelling (FDM) of semi-crystalline polymers via COMSOL: Effect of printing conditions
Prediction of part distortion in Fused Deposition Modelling (FDM) of semi-crystalline polymers via COMSOL: Effect of printing conditions
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DOI：
10.1016/j.cirpj.2021.04.012
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发表时间：
2021-05-15
影响因子：
4.8
通讯作者：
McIlhagger, Alistair
中科院分区：
文献类型：
--
作者：
Samy, Anto Antony;Golbang, Atefeh;McIlhagger, Alistair
在熔融沉积成型中，残余应力和翘曲对3D打印半结晶聚合物的尺寸精度和性能产生不利影响。了解和联系打印条件对零件变形的影响，以优化3D打印过程以获得良好的打印质量，是FDM业面临的主要挑战之一。因此，在这项工作中，通过使用COMSOL中的FDM元素激活期间建立聚合物的结晶动力学、粘弹性和热机械性能与温度变化之间的关系，模拟了各种印刷参数，特别是印刷床温度、层结合、层厚度和栅格图案对累积残余应力和翘曲的影响。据我们所知，这是一种定量预测半结晶聚合物在不同印刷条件下部分变形的新方法。模拟结果表明，当膜层厚度从0.5 mm减小到0.1 mm时，翘曲变形下降89%，残余应力降低24%。与之字形栅格图案相比，应用线栅格图案可分别减少16%和36%的翘曲和残余应力。不同印刷条件下翘曲变形的模拟结果与实验结果吻合较好。本研究的结果可用于预测和/或最小化半结晶3D打印聚合物中的部分变形，方法是模拟打印参数对熔融成形过程中残余应力的影响。官方版权(C)2021
Residual stresses and warpage adversely affect the dimensional accuracy and performance of 3D-printed semi-crystalline polymers in Fused Deposition Modelling (FDM). One of the main challenges in FDM is to understand and relate the impact of printing conditions on part distortion for optimizing the 3D-printing process to achieve good print quality. Hence, the effect of various printing parameters, particularly print bed temperature, layer bonding, layer thickness and raster pattern, on built-up residual stresses and warpage is simulated in this work, by building a relationship between the crystallisation kinetics, viscoelastic and thermo-mechanical properties of the polymer in relation to changes in temperature during FDM using element activation in COMSOL. To the best of our knowledge, this is a novel approach for quantitative prediction of part distortion in FDM of semi-crystalline polymers under various printing conditions. Based on the simulation results, it is observed that a decrease in layer thickness from 0.5 mm to 0.1 mm results in an 89% drop in warpage and a reduction in residual stress of 24%. Applying a line raster pattern reduces warpage and residual stresses by 16% and 36%, respectively in comparison with a zigzag raster pattern. Very good agreement is observed between simulation and experimental results for warpage under various printing conditions. The results of this study can be used to predict and/or minimise part distortion in a semi-crystalline, 3D-printed polymer by simulating the effect of printing parameters on residual stresses during FDM. Crown Copyright (C) 2021