A dynamic model for nozzle clog monitoring in fused deposition modelling

Tlegenov, Yedige; Wong, Yoke San; Hong, G.Y.

doi:10.1108/rpj-04-2016-0054

Cited by 62 publications

(32 citation statements)

References 31 publications

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“…nozzle clogging, overflow, flow disturbances, etc.) from the vibrations of the printing head measured by accelerometers [40,41]. Nevertheless, these dynamical models neglect the printing force that the extruded material applies on the substrate, in spite of the fact that it also contributes to the dynamics of the printing head [40].…”

Section: Accepted Manuscriptmentioning

confidence: 99%

Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing

Comminal

Serdeczny

Pedersen

et al. 2018

Additive Manufacturing

136

130

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Simulations of the material deposition in extrusion-based additive manufacturing Prediction of the strand cross-section as function of the processing parameters Negative linear relationship between the printing force and the printing speed Abstract We propose a numerical model to simulate the extrusion of a strand of semi-molten material on a moving substrate, within the computation fluid dynamics paradigm. According to the literature, the deposition flow of the strands has an impact on the inter-layer bond formation in extrusion-based additive manufacturing, as well as the surface roughness of the fabricated part. Under the assumptions of an isothermal Newtonian fluid and a creeping laminar flow, the deposition flow is controlled by two parameters: the gap distance between the extrusion nozzle and the substrate, and the velocity ratio of the substrate to the average velocity of the flow inside the nozzle. The numerical simulation fully resolves the deposition flow and provides the cross-section of the printed strand. For the first time, we have quantified the effect of the gap distance and the velocity ratio on the size and the shape of the strand. The cross-section of the strand ranges from being almost cylindrical (for a fast printing and with a large gap) to a flat cuboid with rounded edges (for a slow printing and with a small gap), which substantially differs from the idealized cross-section typically assumed in the literature. Finally, we found that the printing force applied by the extruded material on the substrate has a negative linear relationship with the velocity ratio, for a constant gap.

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Section: Accepted Manuscriptmentioning

confidence: 99%

Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing

Comminal

Serdeczny

Pedersen

et al. 2018

Additive Manufacturing

136

130

View full text Add to dashboard Cite

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“…Tlegenov et al 15 studied the vibration acceleration amplitude of two kinds of extruders when the nozzle is blocked, and they summarized the corresponding relationship between the nozzle blockage and the acceleration amplitude. Compared with their research, our research pays more attention to exploring the relationship between feed parameters on nozzle blockage and vibration acceleration amplitude.…”

Section: Discussionmentioning

confidence: 99%

“…The algorithm compensated for the influence of vibration on feed speed and accuracy, so that the direction of motion was opposite to the vibration direction formed in the printing process, and the vibration could be counteracted. Tlegenov et al 15 proposed a nozzle condition testing technique using a vibration sensor for FDM 3D printer; the blockage of the nozzle in the 3D printer was detected by measuring the vibration of the extruder.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation using vibration testing method to optimize feed parameters of color mixing nozzle for fused deposition modeling color 3D printer

Zhang

Shao

et al. 2019

Advances in Mechanical Engineering

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To improve the blockage and printing quality of the color mixing nozzle of fused deposition modeling color 3D printer, the feed parameters of fused deposition modeling color 3D printer were studied by vibration test. The acceleration sensor was fixed up the color mixing nozzle to analyze the vertical vibration of the nozzle. The vibration test of different feed speed, torque, and material were performed under the actual printing condition. Vertical vibration of the nozzle was characterized by an acceleration sensor. The comparative analysis of the actual testing results indicates that the optimum feed parameters are feed torque of triple torque extruder, feed speed of 20 mm/s, and feed material of ABS. Further analysis shows that higher feed torque can be used to improve the printing quality of the color mixing nozzle. The appropriate feed speed of the color 3D printer can not only reduce the accumulation of wire material at a lower speed but also reduce the blockage caused by too-high feed speed. It is proposed that the feed material with smaller flow behavior index and no phase transition in the melting process shows smaller vibration acceleration amplitude.

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“…The amount of wire extruded from the nozzle in unit time will be much smaller than the amount of consumable material when the filling speed is much greater than the extrusion speed, which shall lead to the phenomenon of broken wires and parts difficult to form. The amount of wire extruded from the nozzle in unit time will be much larger than the amount of consumable material when the filling speed is much less than the extrusion speed, which will cause the excess molten wire to pile up on the sprinkler head that leads to each layer material distributed unevenly during forming, thus affecting the production quality [24]. To avoid the above problems, the amount of wire extruded from the nozzle during unit time shall be equal to the amount of consumable material used when filling, that is…”

Section: Complexitymentioning

confidence: 99%

FDM Rapid Prototyping Technology of Complex‐Shaped Mould Based on Big Data Management of Cloud Manufacturing

et al. 2018

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In order to solve the problem of high cost and long cycle in the process of traditional subtractive material manufacturing of a complex-shaped mould, the technology of FDM rapid prototyping is used in combination with the global service idea of cloud manufacturing, where the information of various kinds of heterogeneous-forming process data produced in the process of FDM rapid prototyping is analysed. Meanwhile, the transfer and transformation relation of each forming process data information in the rapid manufacturing process with the digital model as the core is clarified, so that the FDM rapid manufacturing process is integrated into one, thus forming a digital and intelligent manufacturing system for a complex-shaped mould based on the cloud manufacturing big data management. This paper takes the investment casting mould of a spur gear as an example. Through research on the forming mechanism of jet wire, the factors affecting forming quality and efficiency is analysed from three stages: the pretreatment of the 3D model, the rapid prototyping, and the postprocessing of the forming parts. The relationship between the forming parameters and the craft quality is thus established, and the optimization schemes at each stage of this process are put forward through the study on the forming mechanism of jet wire. Through a rapid prototyping test, it is shown that the spur face gear master mould based on this technology can be quickly manufactured with a critical surface accuracy within a range of 0.036 mm–0.181 mm and a surface roughness within the range of 0.007–0.01 μm by only 1/3 the processing cycle of traditional subtractive material manufacturing. It lays a solid foundation for rapid intelligent manufacturing of products with a complex-shaped structure.

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A dynamic model for nozzle clog monitoring in fused deposition modelling

Cited by 62 publications

References 31 publications

Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing

Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing

Experimental investigation using vibration testing method to optimize feed parameters of color mixing nozzle for fused deposition modeling color 3D printer

FDM Rapid Prototyping Technology of Complex‐Shaped Mould Based on Big Data Management of Cloud Manufacturing

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