Investigation of thermal evolution and fluid flow in the hot-end of a material extrusion 3D Printer using melting model

Ufodike, Chukwuzubelu Okenwa; Nzebuka, Gaius Chukwuka

doi:10.1016/j.addma.2021.102502

Cited by 9 publications

(3 citation statements)

References 17 publications

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“…Numerical simulations can shed light on the behavior of the material during printing. This knowledge is essential for creating novel materials and figuring out their limitations [122][123][124][125]. The price of 3D printing can be reduced with the aid of numerical simulations.…”

Section: Numerical Simulationsmentioning

confidence: 99%

Additive Manufacturing Using Agriculturally Derived Biowastes: A Systematic Literature Review

Rahman

Pei

et al. 2023

Bioengineering

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Agriculturally derived biowastes can be transformed into a diverse range of materials, including powders, fibers, and filaments, which can be used in additive manufacturing methods. This review study reports a study that analyzes the existing literature on the development of novel materials from agriculturally derived biowastes for additive manufacturing methods. A review was conducted of 57 selected publications since 2016 covering various agriculturally derived biowastes, different additive manufacturing methods, and potential large-scale applications of additive manufacturing using these materials. Wood, fish, and algal cultivation wastes were also included in the broader category of agriculturally derived biowastes. Further research and development are required to optimize the use of agriculturally derived biowastes for additive manufacturing, particularly with regard to material innovation, improving print quality and mechanical properties, as well as exploring large-scale industrial applications.

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Section: Numerical Simulationsmentioning

confidence: 99%

Additive Manufacturing Using Agriculturally Derived Biowastes: A Systematic Literature Review

Rahman

Pei

et al. 2023

Bioengineering

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“…The flow of the liquid metals could become turbulent as the casting speed increases. The transport of heat within the solidification interfaces can be informed by the fluctuating (or turbulence) flow [1,[4][5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Prediction of Limiting Casting Speed in a Horizontal Direct-Chill Casting through Numerical Modeling and Simulation

Ufodike

Nzebuka

Egole

2023

Metals

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Limiting casting expression speed was obtained and the flow redistribution and thermal history in a horizontal direct-chill (HDC) casting was predicted using the numerical modeling approach. The governing solidification equations were non-dimensionalized to understand the relevant contribution of each term in the solidification processes in the HDC system. The effect of an increase in the casting speed on the flow characteristics and sump length was represented by the Péclet number Pe. Details of the simulation reveal that at a low Pe, the natural convective flow creates minor counter-clockwise recirculating cells in the lower half of the HDC domain. However, at a Pe above 82.75, the minor recirculating cells disappear due to the strong forced convective flow from the upstream. Additionally, an increase in the Pe increases the sump length, strength, and spread of the turbulence field within and beyond the mold region. The limiting casting conditions are computed by predicting the sump length over which the alloy temperature is above the solidus temperature. This gives a simple relation for the casting speed as a function of the geometrical data and the alloy properties. The current work is useful to casting engineers who always rely on trial and error in choosing a new casting speed whenever a new alloy is to be produced. Hence, with the new information and the casting speed relations, it is possible and easy to predict the operating window over which melt break-out can occur during HDC.

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“…Other models that do not account for viscoelastic behavior of the polymer have described the flow physics associated with the transition from stable to unstable extrusion for a generalized Newtonian fluid with decent accuracy 14 . Recent work employing computational fluid dynamics modeling suggests incomplete melting of the polymer upon entering the nozzle and details regarding the flow behavior and temperature distribution inside the nozzle have been analyzed in an effort to aid the development of printers that are compatible with high-rate manufacturing 15 .…”

Section: Introductionmentioning

confidence: 99%

Rheology, crystallization, and process conditions: The effect on interlayer properties in three-dimensional printing

et al. 2022

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Semicrystalline polymers are an attractive feedstock choice for material extrusion (MatEx)-based three-dimensional printing processes. However, the printed parts often exhibit poor mechanical properties due to weak interlayer strength thereby limiting the widespread adoption of MatEx. Improved interlayer strength in the printed parts can be achieved through a combination of process parameter selection and material modification but a physics-based understanding of the underlying mechanism is not well understood. Furthermore, the localized thermal history experienced by the prints can significantly influence the strength of the interlayer welds. In this work, a combined experimental and modeling approach has been employed to highlight the relative impact of rheology, non-isothermal crystallization kinetics, and print geometry on the interlayer strength of printed parts of two semicrystalline polymers, namely, polylactic acid (PLA) and polypropylene (PP). Specifically, the print properties have been characterized as a function of print temperature and print speed. In the case of single road width wall (SRWW) PLA prints, the total crystalline fraction increases due to the broadening of the crystallization window at higher print temperatures and lower print speeds. The results are substantiated by the constitutive modeling results that account for the effects of quiescent crystallization. However, SRWW PP prints display a reduction in the interlayer properties with temperature likely due to significant flow-induced crystallization effects, as suggested by the model. Interestingly, in the case of multilayer PP prints, the repeated heating/cooling cycles encountered during printing counteracts the flow-induced effects leading to an increase in mechanical properties with print temperature consistent with SRWW PLA prints.

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Investigation of thermal evolution and fluid flow in the hot-end of a material extrusion 3D Printer using melting model

Cited by 9 publications

References 17 publications

Additive Manufacturing Using Agriculturally Derived Biowastes: A Systematic Literature Review

Additive Manufacturing Using Agriculturally Derived Biowastes: A Systematic Literature Review

Prediction of Limiting Casting Speed in a Horizontal Direct-Chill Casting through Numerical Modeling and Simulation

Rheology, crystallization, and process conditions: The effect on interlayer properties in three-dimensional printing

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