In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall
This work focuses on simulating the thermal history of a vertical wall consisting of a thermoplastic composite material, poly(ethylene terephthalate) glycol (PETG) with short carbon fiber reinforcement, manufactured using a Big Area Additive Manufacturing (BAAM) system. The incremental deposition pr...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-09-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/19/6486 |
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| author | Felipe Robles Poblete Matthew Ireland Lucinda Slattery William G. Davids Roberto A. Lopez-Anido |
| author_facet | Felipe Robles Poblete Matthew Ireland Lucinda Slattery William G. Davids Roberto A. Lopez-Anido |
| author_sort | Felipe Robles Poblete |
| collection | DOAJ |
| description | This work focuses on simulating the thermal history of a vertical wall consisting of a thermoplastic composite material, poly(ethylene terephthalate) glycol (PETG) with short carbon fiber reinforcement, manufactured using a Big Area Additive Manufacturing (BAAM) system. The incremental deposition process used in additive manufacturing, which corresponds to the repeated deposition of hot material onto cooler material, contributes to the presence of residual stresses and part warping. The prediction of these mechanisms is dependent on thermal history of the part, and the major motivation of this work was to improve the accuracy of finite element (FE) models used to quantify the thermal history of large-format additively manufactured parts. Thermocouples were placed throughout the part at varying heights to measure temperature as a function of time. The FE model developed found a thermal contact conductance between the printed part and the bed of 10 W/m<sup>2</sup>K and convection coefficient values that linearly varied from 3 to 15 W/m<sup>2</sup>K through the wall height when making a temperature comparison with the output from the thermocouples. It is also demonstrated that the FE model with a constant convection coefficient under-predicts model temperature at the beginning of the manufacturing process when compared against the model with a variable convection coefficient. The impact of this difference was seen in the stress values, which were larger for the model with a constant convection coefficient. Finally, a correlation equation was derived which allows the findings to be generalized to other vertical structures manufactured on the BAAM. In summary, this work offers valuable insights on material characterization, real-time thermocouple placement, and FE modeling of large-format additively manufactured parts. |
| first_indexed | 2024-03-10T21:40:55Z |
| format | Article |
| id | doaj.art-8ff31945af1b43ca95b04634ef91fe23 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T21:40:55Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-8ff31945af1b43ca95b04634ef91fe232023-11-19T14:40:33ZengMDPI AGMaterials1996-19442023-09-011619648610.3390/ma16196486In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical WallFelipe Robles Poblete0Matthew Ireland1Lucinda Slattery2William G. Davids3Roberto A. Lopez-Anido4Advanced Structures and Composites Center (ASCC), University of Maine, Orono, ME 04469, USAAdvanced Structures and Composites Center (ASCC), University of Maine, Orono, ME 04469, USADepartment of Physics and Astronomy, University of Maine, Orono, ME 04469, USADepartment of Civil and Environmental Engineering, University of Maine, Orono, ME 04469, USADepartment of Civil and Environmental Engineering, University of Maine, Orono, ME 04469, USAThis work focuses on simulating the thermal history of a vertical wall consisting of a thermoplastic composite material, poly(ethylene terephthalate) glycol (PETG) with short carbon fiber reinforcement, manufactured using a Big Area Additive Manufacturing (BAAM) system. The incremental deposition process used in additive manufacturing, which corresponds to the repeated deposition of hot material onto cooler material, contributes to the presence of residual stresses and part warping. The prediction of these mechanisms is dependent on thermal history of the part, and the major motivation of this work was to improve the accuracy of finite element (FE) models used to quantify the thermal history of large-format additively manufactured parts. Thermocouples were placed throughout the part at varying heights to measure temperature as a function of time. The FE model developed found a thermal contact conductance between the printed part and the bed of 10 W/m<sup>2</sup>K and convection coefficient values that linearly varied from 3 to 15 W/m<sup>2</sup>K through the wall height when making a temperature comparison with the output from the thermocouples. It is also demonstrated that the FE model with a constant convection coefficient under-predicts model temperature at the beginning of the manufacturing process when compared against the model with a variable convection coefficient. The impact of this difference was seen in the stress values, which were larger for the model with a constant convection coefficient. Finally, a correlation equation was derived which allows the findings to be generalized to other vertical structures manufactured on the BAAM. In summary, this work offers valuable insights on material characterization, real-time thermocouple placement, and FE modeling of large-format additively manufactured parts.https://www.mdpi.com/1996-1944/16/19/6486additive manufacturingfinite elementmodelingconductanceconvectionadditive manufacturing |
| spellingShingle | Felipe Robles Poblete Matthew Ireland Lucinda Slattery William G. Davids Roberto A. Lopez-Anido In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall Materials additive manufacturing finite element modeling conductance convection additive manufacturing |
| title | In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall |
| title_full | In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall |
| title_fullStr | In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall |
| title_full_unstemmed | In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall |
| title_short | In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall |
| title_sort | in situ real time temperature mapping and thermal fe simulations of large format 3d printed petg cf vertical wall |
| topic | additive manufacturing finite element modeling conductance convection additive manufacturing |
| url | https://www.mdpi.com/1996-1944/16/19/6486 |
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