Three‐dimensional polymer composite flow simulation and associated fiber orientation prediction for large area extrusion deposition additive manufacturing

Abstract

Material flow and associated fiber orientation are among the most important features in Large Area extrusion deposition Additive Manufacturing (LAAM) of short fiber‐filled composites. Endeavors have been done in 2D flow models, where significant knowledge is achieved in explaining the material anisotropy of the deposited composite parts. Nevertheless, 2D flow models are limited by a couple of assumptions that lose significant characters of the deposition flow. This study is one of the first few that employ a 3D flow model which focuses on the quasi‐steady state of the polymer composite melt flow within the nozzle and the subsequent 90‐degree turning deposition onto the material substrate. The material flow is assumed as a highly viscous Newtonian flow. The fiber orientation is evaluated using the advanced pARD‐RSC fiber orientation tensor evaluation model, via the one‐way weakly‐coupled flow/orientation analysis formulation. Computed results show the fiber orientation state on the entire cross‐section of a deposited bead, which yields a clear view of how the material anisotropy is affected by the locally varied fiber orientation. The 3D‐flow prediction proves that the transverse directional fiber alignments are in high degree of similarity as compared to the over‐predicted results from the simplified 2D planar flows. In addition, the 3D‐model results exhibit a more favorable agreement with the reported experimental data than that yielded by the conventional 2D models.