VOLCO-X: Numerical simulation of material distribution and voids in extrusion additive manufacturing

Autor(es)

de Macedo, Rafael Quelho ^[1] ; Luiz Ferreira, Rafael Thiago ^[1] ; Gleadall, Andrew ^{[2, 3]} ; Ashcroft, Ian ^[2]

Afiliação do(s) autor(es)

^[1] Inst Tecnol Aeronaut, Res Grp Addit Mfg, GPMA, ITA, BR-12228900 Sao Jose Dos Campos, SP - Brazil

^[2] Univ Nottingham, Fac Engn, Ctr Addit Mfg, Univ Pk, Nottingham NG8 1BB - England

^[3] Loughborough Univ, Wolfson Sch Mech & Mfg Engn, Loughborough LE11 3TU, Leics - England

• Tipo de documento: Artigo Científico
• Fonte: ADDITIVE MANUFACTURING; v. 40, APR 2021.
• Citações Web of Science: 0

Resumo

Parts produced by additive manufacturing have final characteristics (such as mechanical properties and dimensional accuracy) strongly dependent on how material is deposited during production. This study presents a modelling concept called VOLCO-X (VOLume COnserving model - eXtended version), which extends a recently developed simulation technique to be able to accurately simulate deposited structures that were not possible with the previous model. A major advantage of the proposed modelling approach is that it does not require any experimental calibration or fitting. The modelling approach is based on a principle of conservation of volume in a voxelized space, in conjunction with a new deposition modelling concept that re-distributes the deposited material when neighboring filaments are in contact. In addition, an acceleration-dependent extrusion rate correction was implemented in the software to predict changes in the material distribution as function of the printing speed, as well as a mechanism to effectively consider possible asymmetry of deposited filaments. The model is shown to accurately predict the geometry and porosity of specimens manufactured by Fused Filament Fabrication (FFF) with varied printing speeds, distance between filaments and extrusion widths. The numerical results correlated well with validation experiments, being able to capture the transition from triangle to diamond void shapes and to predict defects observed in printed parts. VOLCO-X could simulate printing conditions from fully dense structures to under-extruded structures with gaps. It has potential to aid in the design of functional printed parts by predicting the final dimensions, void shapes and void volume fraction of 3D printed parts, and represents an important step towards enabling the predictive simulation of full-sized parts. (AU)

• Processo FAPESP: 17/09419-5 - Projeto hierárquico de componentes multi-material produzidos por impressão 3D
• Beneficiário: Rafael Thiago Luiz Ferreira
• Modalidade de apoio: Bolsas no Exterior - Pesquisa
• Processo FAPESP: 17/22123-8 - Otimização de propriedades mecânicas de componentes construídos por deposição de material fundido através de análise micro mecânica
• Beneficiário: Rafael Quelho de Macedo
• Modalidade de apoio: Bolsas no Exterior - Estágio de Pesquisa - Doutorado
• Processo FAPESP: 16/17835-6 - Análise micromecânica de componentes tipo colmeia fabricados por deposição de material fundido
• Beneficiário: Rafael Quelho de Macedo
• Modalidade de apoio: Bolsas no Brasil - Doutorado