Rapid residual stress prediction and feedback control during fused deposition modeling of PLA

Zhu, Qi; Yu, Kang; Li, Hanqiao; Zhang, Qingqing; Tu, Dawei

doi:10.1007/s00170-021-08158-0

Cited by 18 publications

(10 citation statements)

References 23 publications

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“…The extrusion temperature is crucial in FDM printing. The temperature directly impacts the viscosity and adhesion of the filament, which are deciding factors of the functionality of the print [17]. For parts that are designed for aesthetic purposes, the issue is not a consideration.…”

Section: Common Defects Posed By Fdm Printingmentioning

confidence: 99%

Failures and Flaws in Fused Deposition Modeling (FDM) Additively Manufactured Polymers and Composites

Baechle-Clayton

Loos

Taheri³

et al. 2022

J. Compos. Sci.

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In this review, the potential failures and flaws associated with fused deposition modeling (FDM) or fused filament fabrication (FFF) 3D printing technology are highlighted. The focus of this article is on presenting the failures and flaws that are caused by the operational standpoints and which are based on the many years of experience with current and emerging materials and equipment for the 3D printing of polymers and composites using the FDM/FFF method. FDM or FFF 3D printing, which is also known as an additive manufacturing (AM) technique, is a material processing and fabrication method where the raw material, usually in the form of filaments, is added layer-by-layer to create a three-dimensional part from a computer designed model. As expected, there are many advantages in terms of material usage, fabrication time, the complexity of the part, and the ease of use in FDM/FFF, which are extensively discussed in many articles. However, to upgrade the application of this technology from public general usage and prototyping to large-scale production use, as well as to be certain about the integrity of the parts even in a prototype, the quality and structural properties of the products become a big concern. This study provides discussions and insights into the potential factors that can cause the failure of 3D printers when producing a part and presents the type and characteristics of potential flaws that can happen in the produced parts. Common defects posed by FDM printing have been discussed, and common nondestructive detection methods to identify these flaws both in-process and after the process is completed are discussed. The discussions on the failures and flaws in machines provides useful information on troubleshooting the process if they happen, and the review on the failures and flaws in parts helps researchers and operators learn about the causes and effects of the flaws in a practical way.

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Section: Common Defects Posed By Fdm Printingmentioning

confidence: 99%

Failures and Flaws in Fused Deposition Modeling (FDM) Additively Manufactured Polymers and Composites

Baechle-Clayton

Loos

Taheri³

et al. 2022

J. Compos. Sci.

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“…However, the durability of 3D-printed parts has not been thoroughly investigated or disclosed. Moreover, the fused deposition molding (FDM) process, which is widely employed in 3D printing, often produces substantial thermal residual stress in the printed parts due to repeated heating and cooling cycles [ 30 , 31 ]. This residual stress can be relieved in a humid environment, leading to structural deformation and ultimately affecting the usability and functionality of the component.…”

Section: Introductionmentioning

confidence: 99%

The Mechanical Properties and Degradation Behavior of 3D-Printed Cellulose Nanofiber/Polylactic Acid Composites

Zhang,

Cao,

Jiang

2023

Materials

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Polylactic acid (PLA) has been widely used in many fields because of its good biodegradability, biocompatibility, and renewability. This work studied the degradation behavior and mechanical properties of cellulose nanofiber (CNF)/PLA composites. In vitro degradation experiments of 3D-printed samples were conducted at elevated temperatures, and the degradation characteristics were evaluated by mechanical tests, gel permeation chromatography (GPC), differential scanning calorimetric (DSC), and scanning electron microscope (SEM). The results indicated that the addition of CNF (0.5 wt%) accelerated the degradation rate of PLA. The decreases in number average molecular weight (Mn) and weight average molecular weight (Mw) of composites were 7.96% and 4.91% higher than that of neat PLA, respectively. Furthermore, the tensile modulus of composites was 18.4% higher than that of neat PLA, while the strength was 7.4% lower due to poor interfacial bonding between CNF and PLA. A mapping relationship between accelerated and normal degradation showed that the degradation experienced during 60 days at 37 °C was equivalent to that undergone during 14 days at 50 °C; this was achieved by examining the alteration in Mn. Moreover, the degradation process caused a notable deformation in the samples due to residual stress generated during the 3D printing process. This study provided valuable insights for investigating the in vitro degradation behavior of 3D-printed products.

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“…The study from Zhu et al. [ 11 ] utilizes a feedback control strategy in AM by combining FEA and intelligent algorithms with physical modeling and data analysis. To predict the residual stresses, the back propagation (BP) neural network algorithm is applied.…”

Section: Introductionmentioning

confidence: 99%

“…Out of the four different scanning filling paths, the honeycomb path's stress distribution was the most uniform and resulted in minimal deformation. The study from Zhu et al [11] utilizes a feedback control strategy in AM by combining FEA and intelligent algorithms with physical modeling and data analysis. To predict the residual stresses, the back propagation (BP) neural network algorithm is applied.…”

Section: Introductionmentioning

confidence: 99%

Modeling of Manufacturing Induced Residual Stress in 3D‐Printed Components

Panchasara

Ramakrishnan

Mehle

et al. 2022

Macromolecular Symposia

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The objective of this work is to model the residual stresses that can arise during the production of components using fused deposition modeling (FDM). Thermally induced residual stresses occur during the manufacturing process due to unfavorable thermal conductivity of the polymers used. For this purpose, the G‐code of a 3D printer is first imported into a column interpreter which can be rearranged according to given requirements. This is done using a Visual Basic macro. This geometry data is further processed using a CATIA macro to create a geometry in CATIA. For simplification a circular profile is used, which is extruded over polymer lines and stacked on top of one another. In concert, the time‐varying assignment of the boundary conditions over which the printing process is simulated is performed. The calculations are made in ANSYS Workbench using ANSYS APDL commands. The element activation‐deactivation method is used for the simulation. The thermal simulation is first demonstrated and validated on a sample block and then transferred to the CAD part. The results are imported from Transient Analysis and used as load steps for the Static Structural Analysis, where stresses, strains, and deformations are calculated. The results are then studied to finally print the geometry.

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Rapid residual stress prediction and feedback control during fused deposition modeling of PLA

Cited by 18 publications

References 23 publications

Failures and Flaws in Fused Deposition Modeling (FDM) Additively Manufactured Polymers and Composites

Failures and Flaws in Fused Deposition Modeling (FDM) Additively Manufactured Polymers and Composites

The Mechanical Properties and Degradation Behavior of 3D-Printed Cellulose Nanofiber/Polylactic Acid Composites

Modeling of Manufacturing Induced Residual Stress in 3D‐Printed Components

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