Finite element analysis of residual stress and warpage in a 3D printed semi-crystalline polymer: Effect of ambient temperature and nozzle speed

Samy, Anto Antony; Golbang, Atefeh; Harkin‐Jones, Eileen; Archer, Edward; Tormey, David; McIlhagger, Alistair

doi:10.1016/j.jmapro.2021.08.054

Cited by 40 publications

(36 citation statements)

References 57 publications

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“…Understanding the influence of the stability of the cooling parameters on the correct course of the process of applying successive layers is also an important area requiring thorough analysis. One of the important aspects is the uniform distribution of internal stresses related to the uneven course of the process [22].…”

Section: Introductionmentioning

confidence: 99%

Influence of Extruder’s Nozzle Diameter on the Improvement of Functional Properties of 3D-Printed PLA Products

et al. 2022

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The dynamic growth of the use of polymer construction parts manufactured individually and in a small series makes it necessary to improve additive methods in the areas of materials, equipment and processes. By observing selected phenomena occurring during the processing of polymer materials in other production technologies (e.g., extrusion and injection molding), it is possible to obtain solutions that positively affect the final performance properties of the products obtained in additive manufacturing technologies using thermoplastic filament. The aim of this research was to determine the effect of the diameter of the print head nozzle on the spatial structure (path width) and selected mechanical properties of samples produced by the FFF method with PLA material. The obtained results were compared to the samples with a solid structure produced using injection molding technology. In the experiment, the RepRap device for additive manufacturing was used, with the use of nozzles with diameters of 0.2 mm, 0.4 mm, 0.8 mm and 1.2 mm. The test objects were produced with a layer height of 0.2 mm, full filling (100%) and with constant remaining printing parameters. The conducted research allowed us to conclude that the use of layer heights lower than the standard ones gives favorable results for selected mechanical properties. The use of an extruder nozzle diameter of 0.8 mm allows one to obtain a macrostructure with a high degree of interconnection of layers and paths and favorable mechanical properties. The test results can be used in the construction of functional elements that are produced by fused deposition modeling (FDM) and fused filament fabrication (FFF) methods in prototype, unit and small-lot production.

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Section: Introductionmentioning

confidence: 99%

Influence of Extruder’s Nozzle Diameter on the Improvement of Functional Properties of 3D-Printed PLA Products

et al. 2022

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“…Followed by the deposition process, during cooling, the FDM printed samples gradually warped with respect to the processing conditions. In order to reproduce this phenomenon, a spring foundation was used between the print bed and the simulated model, as this boundary condition allowed the model to warp freely when being cooled down [ 1 , 25 , 35 ]. Throughout the simulation, the print bed temperature was fixed at its respective temperature for each model and maintained as constant.…”

Section: Modelingmentioning

confidence: 99%

“…This was achieved by modifying and incorporating the crystallization physics that was developed by Levy [ 26 , 27 ]. The thermo-mechanical properties of PP were expressed as a function of temperature (T), as was reported in the past that thermo-mechanical properties (

) are highly influenced by the temperature gradient of the system and the degree of crystallization [ 25 , 36 ].…”

Section: Modelingmentioning

confidence: 99%

“…In order to calculate the change in crystallinity with respect to time under non-isothermal crystallization conditions, Nakamura extended the Avrami equation, which is expressed as [ 1 , 25 ]:

…”

Section: Modelingmentioning

confidence: 99%

“…In our previous works, FDM processing parameters such as print bed temperature, layer thickness, nozzle speed, raster pattern including ambient temperature on semi-crystalline polymer were investigated [ 1 , 25 ]. In this study, in order to gain a better understanding of the effect of ambient temperature on amorphous and semi-crystalline polymer towards the internal developed residual stresses and overall warpage, an in-depth analysis was performed.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Ambient Temperature on Part Distortion: A Simulation Study on Amorphous and Semi-Crystalline Polymer

et al. 2022

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Semi-crystalline polymers develop higher amounts of residual stress and part distortion (warpage) compared to amorphous polymers due to their crystalline nature. Additionally, the FDM processing parameters such as ambient temperature play an important role in the resulting residual stresses and part distortion of the printed part. Hence, in this study, the effect of ambient temperature on the in-built residual stresses and warpage of amorphous acrylonitrile-butadiene-styrene (ABS) and semi-crystalline polypropylene (PP) polymers was investigated. From the results, it was observed that increasing the ambient temperature from 50 °C to 75 °C and further to 120 °C resulted in 0.22-KPa and 0.37-KPa decreases in residual stress of ABS, but no significant change in the amount of warpage. For PP, increasing ambient temperature from 50 °C to 75 °C led to a more considerable decrease in residual stress (0.5 MPa) and about 3% increase in warpage. Further increasing to 120 °C resulted in a noticeable 2 MPa decrease in residual stress and a 3.4% increase in warpage. Reduction in residual stress in both ABS and PP as a result of increasing ambient temperature was due to the reduced thermal gradients. The enhanced warpage in PP with increase in ambient temperature, despite the reduction in residual stress, was ascribed to crystallization and shrinkage.

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Injection molding and shear‐induced stress simulation of poly (styrene‐ethylene‐butylene‐styrene) and polypropylene blends

Chen

Yang

et al. 2022

J of Applied Polymer Sci

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In this article, the structure and rheological properties of poly (styrene‐ethylene‐butylene‐styrene) (SEBS) triblock copolymer blends are analyzed. The influence of polypropylene content on the three SEBS blends was discussed, the viscoelastic response and phase structure evolution during injection molding were studied. According to the capillary flow test data, the least square method is used to fit the viscosity parameters of the cross‐WLF model. The filling length of the spline was tested by adjusting the injection molding process parameters, and its accuracy was verified by comparing the filling simulation with the experimental results. Numerical simulation is used to predict the shear rate distribution of injection‐molded samples, and the shear sensitivity and residual stress of SEBS blends with different phase structures are analyzed. Based on the phase structure analysis and rheological properties, this article predicts the filling properties of triblock copolymer composites, which can be used to construct the flow‐induced structure–property relationship of complex polymer blends.

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Finite element analysis of residual stress and warpage in a 3D printed semi-crystalline polymer: Effect of ambient temperature and nozzle speed

Cited by 40 publications

References 57 publications

Influence of Extruder’s Nozzle Diameter on the Improvement of Functional Properties of 3D-Printed PLA Products

Influence of Extruder’s Nozzle Diameter on the Improvement of Functional Properties of 3D-Printed PLA Products

Influence of Ambient Temperature on Part Distortion: A Simulation Study on Amorphous and Semi-Crystalline Polymer

Injection molding and shear‐induced stress simulation of poly (styrene‐ethylene‐butylene‐styrene) and polypropylene blends

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