Modeling of interlayer contact and contact pressure during fused filament fabrication

Journal of Rheology - Tập 63 Số 4 - Trang 655-672 - 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 and data acquisition system are used to monitor the melt pressure, melt temperature, and environmental temperatures while producing parts via fused filament fabrication (FFF). Melt pressures are observed to increase when printing parts with small layer heights, which is attributed to the confined space created between the nozzle and the previous layer (i.e., an exit pressure). These exit pressures (referred to as contact pressure) and the resulting interlayer contact areas are analyzed for 2863 layers created at 21 different processing conditions. The measured contact pressure was found to directly influence the shape of the layers and the resulting interlayer contact. An intimate contact model based on contact pressure is combined with a wetting model to accurately predict the interlayer contact of FFF parts. This pressure-driven intimate contact model for FFF shows strong agreement with the observed interlayer contact. No theoretical model has previously existed for predicting interlayer contact, so this research provides a critical component for developing a comprehensive part strength model. Both the measurements and proposed model are sufficiently simple and accurate for real-time analysis of FFF quality, so the described in-line sensors provide valuable quality insights and are recommended for future researchers, printer manufacturers, and end-users.

Từ khóa


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See supplementary material at https://doi.org/10.1122/1.5093033 for additional information about the derivation and validation of the 2D transient heat analysis used in this work as well as additional measurements and model analyses. The supplementary material includes an analysis comparing results from the four walls (A–D) of condition 1, dimensional analyses including the accuracy of the actual layer heights relative to the nominal layer height and the correlation between Wbond, H, and area with Pcontact, indicating that printed area does not dictate Pcontact. The flow profiles through the FFF nozzle are also discussed in the supplementary material along with validation and additional results from the wetting model. Supplementary raw data, including Wbond, Pcontact, and predicted Wbond for each layer of the 21 conditions, are provided in the “bond and pressure raw data” file. Please also view the multimedia video of the printing process corresponding with Fig. 4.

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Journal of Rheology

Tập 63 Số 4

655-672

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