Title: Process Sensitivity Study of Metal Fused Filament Fabrication (MF3) Using Finite Element-Based Process Simulation Approach

Authors: Mohammad Qasim Shaikh, Paramjot Singh, Pierre-Yves Lavertu, Kunal H Kate and Sundar V. Atre

DOI: 10.33599/nasampe/s.20.0187

Abstract: Metal fused filament fabrication (MF3) combines fused filament fabrication and sintering processes to fabricate complex metal components. In design for MF3 (DfMF3), it is important to understand how part design, printing parameters and material properties of filament affect MF3 printing process in terms of processability, part quality, and ensuing properties. Understanding the interrelationships between material-process-design variations is essential to leverage the potential of MF3 and deploy it to industrial applications. The goal of the study is to conduct a sensitivity analysis to identify the significance of each input parameter in terms of influence on the output parameters. FEA-based simulations were used to estimate the process outcome in response to variable inputs. However, simulating and optimizing the MF3 printing process is a complex problem having a number of linked geometry, process and material variables to be considered that influence the process output parameters like deflection, warpage, residual stress, thermal history and print time. Having multiple objective functions for process optimization makes it very difficult to identify critical parameters for designing part geometry, processing conditions and powder-binder feedstock for MF3. Towards the goal of identifying the level of significance of various input variables during MF3 process, a systematic procedure for sensitivity analysis has been successfully developed for the printing phase of the MF3 process. In this sensitivity analysis, all geometry, process and material input variables were varied within a meaningful window one at a time, and influence on process outcome was noted in terms of output parameters. The present sensitivity analysis procedure is expected to be an invaluable tool not only for the materials engineer who has to develop an optimal formulation of MF3 material, but also for the design engineer who has to determine the critical input parameters for given design targets, as well as for the production engineer who has to optimize and monitor the production stage.

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Conference: SAMPE 2020 | Virtual Series

Publication Date: 2020/06/01

SKU: TP20-0000000187

Pages: 17

Price: FREE