Viscoelastic simulation and optimisation of the polymer flow through the hot-end during filament-based material extrusion additive manufacturing

Serdeczny, Marcin P.; Comminal, Raphaël; Mollah, Md. Tusher; Pedersen, David Bue; Spangenberg, Jon

doi:10.1080/17452759.2022.2028522

Cited by 15 publications

(8 citation statements)

References 24 publications

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“…[39] AM is a single-step, affordable, and almost waste-free technique for manufacturing models, prototypes, and end-user products with a minimum amount of material and time. Recently, it has been shown that fused filament fabrication (FFF) AM or material extrusion (MEX) AM [40] can be used to print polymerbonded magnets with complex structures. [28,33,[41][42][43][44][45] MEX technology works by heating up cylindrical thermoplastic filaments above the softening point.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Hard Magnetic Passive Shims to Increase Field Homogeneity of a Halbach Magnet

et al. 2023

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Obtaining a highly homogeneous magnetic field is desired for field‐controlled applications. For example, the resolution of magnetic analysis methods can be improved by generating a stronger and more homogeneous field over the region of interest (ROI). A set of 3D‐printed passive shims is fabricated using additive manufacturing to improve the magnetic field homogeneity of a Halbach magnet assembly. The feedstock is a custom acrylonitrile butadiene styrene (ABS)‐hard magnet composite filament filled with 60% wt. isotropic NdFeB. Additionally, a method for investigating the remanence is developed and validated. The result reveals a good agreement between the new method and existing measurement techniques for the remanence of permanent magnets. It is also shown that the additive manufacturing procedure has negligible effects on the magnetic properties. Performing a parametric study over a rectangular ROI, an optimized shim configuration is achieved. In the optimized and 3D‐printed configuration, the average norm of the magnetic flux density, Bnorm, is increased by 13% and, more importantly, a 43% increase in the magnetic uniformity is obtained. These results highlight the great potential of freeform manufacturing, namely, additive manufacturing, to tailor the properties of magnet structures.

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Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Hard Magnetic Passive Shims to Increase Field Homogeneity of a Halbach Magnet

et al. 2023

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“…Because of the variability in the process and final part properties due to thermal gradients, researchers have modeled the heat transfer within the MatEx process (Pourali and Peterson, 2019; Xia et al , 2018; Nahar and Gurrala, 2022; Driezen and Herrmann, 2022; Duarte et al , 2021) and implemented models to predict the strength of the welds within the process (Coogan and Kazmer, 2020; Peterson and Kazmer, 2022). As part of those efforts, researchers have investigated modeling of the melt temperature within the MatEx hot end (Trofimov et al , 2022; Xia et al , 2018; Osswald et al , 2018; Moretti et al , 2021; Prajapati et al , 2018; Van Waeleghem et al , 2022; Serdeczny et al , 2020b; Kattinger et al , 2022; Go et al , 2017; Mazzei Capote et al , 2021; Luo et al , 2020; Serdeczny et al , 2022). Models range from simpler analytical models (Phan et al , 2018) to numerical models that leverage axisymmetric assumptions (Nzebuka et al , 2022).…”

Section: Introductionmentioning

confidence: 99%

“…These include whether the melt forms in the nozzle contraction zone or upstream (Osswald et al , 2018; Serdeczny et al , 2020b), Newtonian and non-Newtonian fluid behavior (Van Waeleghem et al , 2022) and variable thermal properties (Nzebuka et al , 2022). For most of these works, the most common hot end design (Krishnanand et al , 2021) is assumed, though some researchers have investigated different designs (Serdeczny et al , 2022).…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…There are studies that show model validation data for different volumetric flow rates and temperature setpoints, and some have investigated the effect of nozzle orifice diameter/design (Nzebuka et al , 2022; Serdeczny et al , 2022). In most cases, the pressure required to extrude material is the metric for model validation (Serdeczny et al , 2022; Osswald et al , 2018; Mazzei Capote et al , 2021; Serdeczny et al , 2020b; Kattinger et al , 2022). Infrared (IR) thermography has been used to validate models of the melt temperature at the exit of the nozzle for standard hot ends (Roy et al , 2019; Trofimov et al , 2022; Lepoivre et al , 2022; Moretti et al , 2021), though a full set of thermography data has not been used to validate a melting model.…”

Section: Introductionmentioning

confidence: 99%

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Steady melting in material extrusion additive manufacturing

Colon,

Kazmer,

Peterson

et al. 2023

RPJ

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Purpose A main cause of defects within material extrusion (MatEx) additive manufacturing is the nonisothermal condition in the hot end, which causes inconsistent extrusion and polymer welding. This paper aims to validate a custom hot end design intended to heat the thermoplastic to form a melt prior to the nozzle and to reduce variability in melt temperature. A full 3D temperature verification methodology for hot ends is also presented. Design/methodology/approach Infrared (IR) thermography of steady-state extrusion for varying volumetric flow rates, hot end temperature setpoints and nozzle orifice diameters provides data for model validation. A finite-element model is used to predict the temperature of the extrudate. Model tuning demonstrates the effects of different model assumptions on the simulated melt temperature. Findings The experimental results show that the measured temperature and variance are functions of volumetric flow rate, temperature setpoint and the nozzle orifice diameter. Convection to the surrounding air is a primary heat transfer mechanism. The custom hot end brings the melt to its setpoint temperature prior to entering the nozzle. Originality/value This work provides a full set of steady-state IR thermography data for various parameter settings. It also provides insight into the performance of a custom hot end designed to improve the robustness of melting in MatEx. Finally, it proposes a strategy for modeling such systems that incorporates the metal components and the air around the system.

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Influence of the Printing Direction on the Surface Appearance in Multi-material Fused Filament Fabrication

Tonello,

Mollah,

Weiss

et al. 2024

Computer-Aided Design and Computer Graphics

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Viscoelastic simulation and optimisation of the polymer flow through the hot-end during filament-based material extrusion additive manufacturing

Cited by 15 publications

References 24 publications

Additive Manufacturing of Hard Magnetic Passive Shims to Increase Field Homogeneity of a Halbach Magnet

Additive Manufacturing of Hard Magnetic Passive Shims to Increase Field Homogeneity of a Halbach Magnet

Steady melting in material extrusion additive manufacturing

Influence of the Printing Direction on the Surface Appearance in Multi-material Fused Filament Fabrication

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