A deforming‐mesh finite‐element approach applied to the large‐translation and free‐surface scenario of fused deposition modeling

Abstract

AbstractA numerical study of the fused deposition modeling (FDM) process using a boundary‐conforming free‐surface finite element approach is performed. Due to the complexity of the FDM process, among all of its parts, we focus on the deposition and spreading of an individual filament. The polymer behavior, that is, the shear rate dependent and temperature‐dependent viscosity, is included by the Cross‐WLF viscosity model. The moving domain is addressed by the virtual region mesh update method, which, in the present article, is extended to free‐surface problems. The particularity of dividing the mesh domain into an activated and a deactivated domain makes it possible to handle large translatory mesh deformation. In this work, we make use of the level of detail offered by a boundary‐conforming approach regarding both topology accuracy and the imposition of boundary conditions in order to study the deposition of a single filament at a small scale. Parameters with a direct impact on the mechanical properties of the final object can be straightforwardly computed by a boundary‐conforming approach, for instance, the cross‐section, the contact area, the temperature distribution, and the heat fluxes over the surfaces. The presented approach is validated by a two‐dimensional benchmark test case before the numerical results of the three‐dimensional simulation of the filament deposition are shown.