Title: Influence of Process Conditions on the Extrudate and Inter-Bead Geometries in Extrusion Deposition Additive Manufacturing

Authors: Pasita Pibulchinda, Eduardo Barocio, Anthony J. Favaloro, R. Byron Pipes

DOI: 10.33599/nasampe/c.22.0036

Abstract: The current work investigates the influence of relevant EDAM processing conditions on the final cross-sectional geometry of a bead and inter-bead area through numerical and experimental approaches in the absence of tamping or rolling. The latter two processes are not considered in this study, although successful void elimination may be accomplished by both approaches. Specifically, two key processes of the EDAM process are studied, namely: (i) flow of 90° angle turn as the extrudate exits the nozzle and is laid down on the previous layer or the substrate, and (ii) flow of an extrudate deposited adjacent to the previously compacted extrudate. The processing parameters considered are nozzle height from the substrate, the ratio of print bed velocity to extrusion velocity, and the distance between the adjacent lateral beads. These three parameters are the most relevant to processing because they influence the velocity gradients, the orientation of discontinuous fibers, and the geometries of the printed bead and inter-bead voids. The simulations utilize an anisotropic viscous flow model implemented using the smoothed particle hydrodynamics method in Abaqus. The simulation accounts for the coupling between fiber orientation and anisotropic viscous flow behavior. In addition, fiber orientation vectors are evolved under the assumption of affine motion, equivalent to Jeffery’s equation [1]. The simulation results are compared with printed bead geometries produced using similar processing conditions and this comparison validates the modeling approach as useful for predicting bead and inter-bead voids geometries. [1] Jeffery, G. B. (1922). The motion of ellipsoidal particles immersed in a viscous fluid. Proceedings of the Royal Society of London. Series A, Containing papers of a mathematical and physical character, 102(715), 161-179.

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Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000036

Pages: 15

Price: $30.00