Melt exit flow modelling and experimental validation for fused filament fabrication: From Newtonian to non-Newtonian effects

被引:34
作者
Van Waeleghem, T. [1 ]
Marchesini, Flavio H. [1 ]
Cardon, Ludwig [1 ]
D'hooge, Dagmar R. [2 ,3 ]
机构
[1] Univ Ghent, Ctr Polymer Mat & Technol CPMT, Technol Pk 130, B-9052 Ghent, Belgium
[2] Univ Ghent, Lab Chem Technol LCT, Technol Pk 125, B-9052 Ghent, Belgium
[3] Univ Ghent, Ctr Text Sci & Engn CTSE, Technol Pk 70a, B-9052 Ghent, Belgium
关键词
Fused filament fabrication; Swelling; Rheology; Process control; 3D printing; NORMAL STRESS DIFFERENCE; EXTRUDATE SWELL; VISCOELASTIC FLUIDS; LIQUEFIER DYNAMICS; FEEDSTOCK MATERIAL; DEPOSITION FLOW; POLYMER MELT; EXTRUSION; COMPOSITES; CERAMICS;
D O I
10.1016/j.jmapro.2022.03.002
中图分类号
T [工业技术];
学科分类号
08 ;
摘要
Fused filament fabrication (FFF) is an important additive manufacturing technique to produce complex poly-meric parts in fields such as prototyping, medical devices and sporting equipment. An outstanding challenge is the detailed understanding of the flow behaviour once the filament has been molten, as it determines the structure and stability. Here one can distinguish between the flow downstream the nozzle exit and the shape variations once the flow is deposited on the printing plate. Advanced modelling techniques are recommended but currently one typically assumes Newtonian flow, despite that conventional large-scale extrusion studies have highlighted the relevance of the viscoelastic nature of thermoplastic polymers, specifically upon the die exit. In the present contribution, polypropylene (PP) FFF flow is simulated at a reference FFF temperature of 473 K with ANSYS Polyflow by inputting Phan-Thien-Tanner (PTT) viscoelastic parameters that have been previously validated, based on both rheological and conventional extrusion slit die swell measurements. The suitability of these PTT parameters is further confirmed by comparing simulated and experimental FFF swelling data, with a coefficient of determination of 0.916. Benefiting from this validation, the flow model is reliably used to highlight that both the FFF processing parameters, e.g. temperature and printing speed, and machine parameters, e.g. nozzle length and diameter, have a large impact on the viscoelastic exit flow. A sensitivity analysis on the viscoelastic parameters additionally highlights the relevance of dedicated rheological data to understand FFF swelling and to accurately simulate the subsequent deposition stage.
引用
收藏
页码:138 / 150
页数:13
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