TY - JOUR
T1 - A part-level simulation method considering thermal-mechanical contact between multiple filaments for material extrusion processes
AU - Meng, Junfeng
AU - Liu, Jianhua
AU - Xia, Huanxiong
AU - Ao, Xiaohui
AU - Zhang, Wang
N1 - Publisher Copyright:
© 2024 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.
PY - 2025
Y1 - 2025
N2 - Part-level thermal-mechanical simulation with filament resolution is currently a significant challenge for material extrusion processes. This paper proposed a novel method to achieve part-level and high-fidelity simulation for such processes, where the physical behaviours of heat transfer, viscoelasticity, dynamics, and contact are comprehensively considered. This method integrates a sophisticated thermal-mechanical contact model with a thermo-viscoelastic dynamic model. The kinematic and dynamic behaviours of the filaments were described based on the theory of discrete differential geometry, and the contact force and heat transfer between multiple filaments were modelled by using a newly defined contact element with spring-dashpot forces and heat conduction. The contact parameters were determined, and the accuracy was validated through contact experiments. The contact reheating and temperature distribution were quantified, and the effects of the printing parameters on the contact heat transfer and deformation were examined. Several part-level cases were simulated to demonstrate its capability in industrial applications.
AB - Part-level thermal-mechanical simulation with filament resolution is currently a significant challenge for material extrusion processes. This paper proposed a novel method to achieve part-level and high-fidelity simulation for such processes, where the physical behaviours of heat transfer, viscoelasticity, dynamics, and contact are comprehensively considered. This method integrates a sophisticated thermal-mechanical contact model with a thermo-viscoelastic dynamic model. The kinematic and dynamic behaviours of the filaments were described based on the theory of discrete differential geometry, and the contact force and heat transfer between multiple filaments were modelled by using a newly defined contact element with spring-dashpot forces and heat conduction. The contact parameters were determined, and the accuracy was validated through contact experiments. The contact reheating and temperature distribution were quantified, and the effects of the printing parameters on the contact heat transfer and deformation were examined. Several part-level cases were simulated to demonstrate its capability in industrial applications.
KW - Multiple filaments
KW - contact deformation and reheating
KW - discrete differential geometry
KW - part-level simulation
KW - thermal-mechanical contact
UR - https://www.scopus.com/pages/publications/85213710873
U2 - 10.1080/17452759.2024.2441944
DO - 10.1080/17452759.2024.2441944
M3 - Article
AN - SCOPUS:85213710873
SN - 1745-2759
VL - 20
JO - Virtual and Physical Prototyping
JF - Virtual and Physical Prototyping
IS - 1
M1 - e2441944
ER -