SHAPE DISTORTION OF FUSED DEPOSITION MODELING PARTS EVALUATED BY FINITE ELEMENT ANALYSES

por: Sérgio Evangelista, Alexandre Malavolta, Mariano Eduardo Moreno, Jose Rubert

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Ano: 2019

Instituições de ensino: Universidade Federal de São Carlos, Universidade Federal de São Carlos, Universidade Federal de São Carlos, Universidade Federal de São Carlos

Idioma: Ingles

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Resumo

Additive manufacturing (AM), popularly embracing expressions such as 3D printing, has become an important process to create components or prototypes before final release to commercialization or even to create a final functional product. A popular AM method is the Fused Deposition Modeling (FDM), a material extrusion technology which is characterized by a pre-heating that increases the material temperature to its melting point so that it can be extruded through a nozzle in a controlled manner. An important design consideration when using FDM is to account for the macroscopic mechanical behavior of the final printed part, e.g., its geometric distortion. In this context, it is investigated the problem of geometric distortion of a specimen made of acrylonitrile butadiene styrene (ABS), an AM material which is a common thermoplastic polymer used in FDM processes. The procedure is based on a sequential set of uncoupled thermal and thermomechanical finite element analyses (FEA) combined to an element birth-and-death strategy available in the software ANSYS®. The problem is analyzed under several loading and boundary conditions in order to evaluate the progressive effect of residual stresses accumulated from previously deposited material. The obtained results are discussed and compared with analytical and numerical data presented by other researchers. This investigation shows that the proposed tool can evaluate the distortion in terms of geometric shape pattern, while the critical displacement values are quite different from the experimental data. Despite of that and compared to other authors, over than 80% reduction on the processing time is possible with this approach.


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