Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters
The material extrusion additive manufacturing (MEAM) process for polymers seems straightforward. However, several controlled and uncontrolled factors affect the 3D printed product quality, e.g., MEAM process parameters, thermomechanical properties of the material, and part design. Therefore, it is c...
| Main Authors: | , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-08-01
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| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/14/17/3482 |
| _version_ | 1797493600655769600 |
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| author | Ans Al Rashid Muammer Koç |
| author_facet | Ans Al Rashid Muammer Koç |
| author_sort | Ans Al Rashid |
| collection | DOAJ |
| description | The material extrusion additive manufacturing (MEAM) process for polymers seems straightforward. However, several controlled and uncontrolled factors affect the 3D printed product quality, e.g., MEAM process parameters, thermomechanical properties of the material, and part design. Therefore, it is crucial to understand these interlinked factors of part geometry, material properties, and 3D printing (3DP) process parameters to optimize 3D printed product quality. The numerical models and simulation tools can predict the thermomechanical performance of the MEAM process under given input parameters (material, design, and process variables) and reduce the research and development costs significantly. However, the numerical models and tools need further exploration and validation of simulation predictions for their adaptability and reliability. Therefore, in this study, numerical simulations were performed to observe the impact of process parameters on the part quality of MEAM 3D printed components. The two crucial process parameters (i.e., extrusion temperature and layer resolution) were varied while keeping the other process parameters, part geometry (tensile testing coupon), and material properties (acrylonitrile butadiene styrene (ABS)) constant. These two process parameters were sequentially optimized for optimum part quality, first by varying the extrusion temperature and secondly by changing the printing resolution using the optimum printing temperature. The 3DP process quality was evaluated in terms of dimensional accuracy, distortions, and residual stresses. Finally, the specimens were 3D printed under similar process conditions to validate the numerical model predictions. |
| first_indexed | 2024-03-10T01:22:21Z |
| format | Article |
| id | doaj.art-d22bc923c80f4b93a076aeb54efa1a1a |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-10T01:22:21Z |
| publishDate | 2022-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-d22bc923c80f4b93a076aeb54efa1a1a2023-11-23T13:57:44ZengMDPI AGPolymers2073-43602022-08-011417348210.3390/polym14173482Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process ParametersAns Al Rashid0Muammer Koç1Division of Sustainable Development, College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha 34110, QatarDivision of Sustainable Development, College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha 34110, QatarThe material extrusion additive manufacturing (MEAM) process for polymers seems straightforward. However, several controlled and uncontrolled factors affect the 3D printed product quality, e.g., MEAM process parameters, thermomechanical properties of the material, and part design. Therefore, it is crucial to understand these interlinked factors of part geometry, material properties, and 3D printing (3DP) process parameters to optimize 3D printed product quality. The numerical models and simulation tools can predict the thermomechanical performance of the MEAM process under given input parameters (material, design, and process variables) and reduce the research and development costs significantly. However, the numerical models and tools need further exploration and validation of simulation predictions for their adaptability and reliability. Therefore, in this study, numerical simulations were performed to observe the impact of process parameters on the part quality of MEAM 3D printed components. The two crucial process parameters (i.e., extrusion temperature and layer resolution) were varied while keeping the other process parameters, part geometry (tensile testing coupon), and material properties (acrylonitrile butadiene styrene (ABS)) constant. These two process parameters were sequentially optimized for optimum part quality, first by varying the extrusion temperature and secondly by changing the printing resolution using the optimum printing temperature. The 3DP process quality was evaluated in terms of dimensional accuracy, distortions, and residual stresses. Finally, the specimens were 3D printed under similar process conditions to validate the numerical model predictions.https://www.mdpi.com/2073-4360/14/17/3482material extrusionadditive manufacturingfused filament fabricationprocess simulationresidual stresseswarpage |
| spellingShingle | Ans Al Rashid Muammer Koç Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters Polymers material extrusion additive manufacturing fused filament fabrication process simulation residual stresses warpage |
| title | Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters |
| title_full | Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters |
| title_fullStr | Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters |
| title_full_unstemmed | Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters |
| title_short | Experimental Validation of Numerical Model for Thermomechanical Performance of Material Extrusion Additive Manufacturing Process: Effect of Process Parameters |
| title_sort | experimental validation of numerical model for thermomechanical performance of material extrusion additive manufacturing process effect of process parameters |
| topic | material extrusion additive manufacturing fused filament fabrication process simulation residual stresses warpage |
| url | https://www.mdpi.com/2073-4360/14/17/3482 |
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