In-line rheological monitoring of fused deposition modeling

Journal of Rheology - Tập 63 Số 1 - Trang 141-155 - 2019
Timothy J. Coogan1,2, David O. Kazmer3,1
1Department of Plastics Engineering, University of Massachusetts Lowell 1 , Lowell, Massachusetts 01854
2Saint-Gobain Research North America 2 , Northborough, Massachusetts 01532
32Saint-Gobain Research North America, Northborough, Massachusetts 01532

Tóm tắt

An in-line rheometer has been incorporated into a fused deposition modeling printer for the first time by designing a modified nozzle with a custom pressure transducer and a thermocouple for measuring the processed melt temperature. Additionally, volumetric flow rates and shear rates were monitored by counting the stepper motor pulses as well as the pulses from a custom filament encoder to account for filament slippage and skipped motor steps. The incorporation of the sensors and the design and development of the in-line rheometer are described; and pressures, temperatures, and viscosities within the 3D printing nozzle are presented. The in-line rheometer was validated against traditional, off-line rotational rheology and capillary rheology measurements by analyzing two polymeric materials: polycarbonate and high-impact polystyrene. A variety of rheological corrections were considered for the in-line rheometer, including entrance effects, non-Newtonian corrections, shear heating, pressure effects, and temperature fluctuations/inaccuracies. Excellent agreement was obtained between the in-line and off-line rheometers after applying the most critical corrections, which were found to be entrance effects, non-Newtonian corrections, and temperature inaccuracies. After applying the appropriate corrections, the in-line rheometer provides an accurate viscosity measurement that can be used for real-time monitoring and process control.

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See supplementary material at https://doi.org/10.1122/1.5054648 for additional details regarding the design of the in-line rheometer components, validation of the volumetric flow rates calculated by the pulses from the stepper motor and encoder, additional equations and analysis for calculating entrance pressure effects, and the shear heating analysis in the FDMRheo. The final, corrected viscosities are tabulated to compare the values from the three rheometers. The raw data of the equilibrated pressures, shear rates, viscosities, etc. are also tabulated in the supplementary material. Supplementary raw data, including the transient pressure, voltage, shear stress, shear rate, viscosity, and temperature, are provided in individual raw data files: HIPS 225C 1_72mmL, HIPS 250C 1_72mmL, HIPS 275C 1_72mmL, PC 250C 1_72mmL, PC 270C 1_72mmL, and PC 290C 1_72mmL. Note that these files are only for one of the two tests at each condition for the 1.72 mm length nozzle tip; the raw data provided contain data every 8 ms (data were collected every 4 ms) to reduce file sizes. Two sets of time data are included in each raw data file; “Time” refers to the time for the pressure, voltage, shear stress, shear rate, and viscosity data, while “Temp Time” refers to the time for the nozzle temperature data, which is collected at a slower rate.