Fusion Bonding Simulations of Semi-Crystalline Polymer Composites in the Extrusion  Deposition Additive Manufacturing Process

Barocio, Eduardo; Brenken, Bastian; Favaloro, Anthony J.; Ramírez, Jorge Alberto; Kunc, Vlastimil; Pipes, R. Byron

doi:10.12783/asc2017/15395

Cited by 15 publications

(9 citation statements)

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“…The use of computation and finite element method is a powerful tool to predict the mechanical properties, but also to model the 3D printing process itself. FEM has been used to model the FFF manufacturing process [107,108,109] as well as the large-scale variation of this process [110,111,112,113,114]. Nevertheless, process simulation of the FFF process is beyond the scope of this review paper.…”

Section: Modeling With Computational Methodsmentioning

confidence: 99%

“…Since inter-layer properties are strongly dependent on processing conditions, Barocio et al [112,113] developed a method to predict the evolution of inter-layer properties during the printing process, thereby closing the gap between processing conditions and part performance. This approach has been validated for fiber reinforced semi-crystalline polymers and consists of coupling the temperature evolution, polymer crystallization and melting, and polymer diffusion.…”

Section: Modeling With Computational Methodsmentioning

confidence: 99%

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Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches

et al. 2019

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The increase in accessibility of fused filament fabrication (FFF) machines has inspired the scientific community to work towards the understanding of the structural performance of components fabricated with this technology. Numerous attempts to characterize and to estimate the mechanical properties of structures fabricated with FFF have been reported in the literature. Experimental characterization of printed components has been reported extensively. However, few attempts have been made to predict properties of printed structures with computational models, and a lot less work with analytical approximations. As a result, a thorough review of reported experimental characterization and predictive models is presented with the aim of summarizing applicability and limitations of those approaches. Finally, recommendations on practices for characterizing printed materials are given and areas that deserve further research are proposed.

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Section: Modeling With Computational Methodsmentioning

confidence: 99%

Section: Modeling With Computational Methodsmentioning

confidence: 99%

Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches

et al. 2019

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“…Wetting starts as soon as the surfaces are in contact, and the molecular diffusion barrier between the interfaces of the molten resin disappears. By the end of the surface contact stage, the molecular chains move freely through the interface to form a bonding neck, and then the interfacial bonding is terminated [28,29]. Figure 9 illustrates the formation process of the bonding neck during the printing process.…”

Section: Formation and Calculation Of Interfacial Bonding Neckmentioning

confidence: 99%

Interfacial Bonding Mechanism and Mechanical Performance of Continuous Fiber Reinforced Composites in Additive Manufacturing

Fan

Shan

Zou

et al. 2021

Chin. J. Mech. Eng.

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The additive manufacturing of continuous fiber composites has the advantage of a high-precision and efficient forming process, which can realize the lightweight and integrated manufacturing of complex structures. However, many void defects exist between layers in the printing process of additive manufacturing; consequently, the bonding performance between layers is poor. The bonding neck is considered a key parameter for representing the quality of interfacial bonding. In this study, the formation mechanism of the bonding neck was comprehensively analyzed. First, the influence of the nozzle and basement temperatures on the printing performance and bonding neck size was measured. Second, CT scanning was used to realize the quantitative characterization of bonding neck parameters, and the reason behind the deviation of actual measurements from theoretical calculations was analyzed. When the nozzle temperature increased from 180 to 220 °C, CT measurement showed that the bonding neck diameter increased from 0.29 to 0.34 mm, and the cross-sectional porosity reduced from 5.48% to 3.22%. Finally, the fracture mechanism was studied, and the influence of the interfacial bonding quality on the destruction process of the materials was determined. In conclusion, this study can assist in optimizing the process parameters, which improves the precision of the printing parts and performance between the layers.

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“…The readers are suggested to refer to the original article for detail understanding of the relation between entanglement number, molecular weight, and fracture toughness. Very recently, Barocio et al 95 developed a model by coupling the bonding process of adjacent beads to predict the degree of bonding, temperature history, crystallization, and diffusion of semi-crystalline polymer chains. The coupling was implemented in UMATHT user subroutine in ABAQUS !, and the degree of bonding was calculated through simulated beads of different layers with different cooling and crystallization rates.…”

Section: Bond Formation Crystallization and Bead-bondingmentioning

confidence: 99%

Review on process model, structure-property relationship of composites and future needs in fused filament fabrication

Papon

Haque

2020

Journal of Reinforced Plastics and Composites

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This paper presents the state-of-the-art of additive manufacturing of composites for processing functional, load-bearing components. A general overview of different additive manufacturing methods is provided, and specific attention is focused on fused filament fabrication-based composites processing. Different process modeling strategies are summarized, and key aspects of these models are discussed. Significant results such as thermal and fluid flow characteristics, effects of nozzle geometry on melt flow, fiber orientation, bead spreading, and solidification, the formation of residual stresses, and deformation behavior are discussed from computational modeling perspective. The scientific advancement, model limitations, and future modeling needs are prescribed reviewing the current works. A general overview of material development in nano-micro-macro-scale reinforcement is also presented. Different length-scales of reinforcement has its own challenges and promises. The continuous fiber reinforcement has a great potential for being the next-generation composites manufacturing technology. However, the challenges in reducing the void content, better bonding between the fiber–matrix, and layer-layer adhesion, and process uncertainty are some of the key areas yet to advance. Based on the current limitations on computational modeling, materials development, and process modeling studies, future research needs and recommendations are provided.

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Fusion Bonding Simulations of Semi-Crystalline Polymer Composites in the Extrusion Deposition Additive Manufacturing Process

Cited by 15 publications

References 0 publications

Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches

Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches

Interfacial Bonding Mechanism and Mechanical Performance of Continuous Fiber Reinforced Composites in Additive Manufacturing

Review on process model, structure-property relationship of composites and future needs in fused filament fabrication

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