Smoothed particle hydrodynamics (SPH) modeling of fiber orientation in a 3D printing process

We present a numerical study of the fused deposition modeling 3D printing process of fiber-reinforced polymers by means of Smoothed Particle Hydrodynamics (SPH). For this purpose, a classical microstructure-based fiber suspension model coupled with a constitutive model for the suspending polymer is implemented within an SPH framework. The chosen model is reviewed, together with the details and specificities of its implementation in SPH. The results for several representative cases are then presented, mainly in terms of contours of fiber orientation tensor components and orientation distributions across the deposited layer thickness. The impact of the fiber concentration and its aspect ratio in a semi-concentrated regime and the effect of the ratio between extrusion and substrate velocities are investigated. Some insights into the link between the flow field and fiber orientation evolution within the printing head and as the material exits the nozzle are given. The main findings lie in the prediction of a skin/core structure in the deposited layer in which the skin regions exhibit a higher fiber alignment with respect to the core region. This effect is found to be enhanced by an increase in fiber concentration and to be sensitive to the substrate-to-extrusion velocity ratio. It is indeed enhanced in cases where the substrate velocity is low compared to the extrusion velocity and accompanied by a larger swelling of the deposit at the nozzle exit. Published by AIP Publishing.