Abstract
Three-dimensional prototypes and final products are commonly fabricated using the material extrusion (ME) process in additive manufacturing applications. However, these prototypes and products are limited to a single material using the ME process due to technical challenges. Deposition of plastic on another dissimilar plastic substrate requires proper control of printing temperature during an ME process due to differences in melting temperatures of dissimilar plastics. In this paper, deposition of PLA filament on an ABS substrate during an ME process is investigated using finite element analysis. A heat transfer finite element (FE) model for the extrusion process is proposed to estimate the parameters of the ME machine for the formulation of a heat flux model. The effects of printing temperature and the stand-off distance on temperature distributions are investigated using the proposed FE model for the extrusion process. The heat flux model is implemented in a proposed heat transfer FE model of single bead deposition of PLA on an ABS plate. From this FE model of deposition, temperature histories during the ME deposition process are estimated. The results of temperature histories are compared with experiments. Using the calibrated FE model, a proper heating temperature of ABS for deposition of PLA is evaluated.
Highlights
The material extrusion (ME) process is a widely used additive manufacturing technique to create three-dimensional prototypes, and final products direct from a computer model
An acrylonitrile butadiene styrene (ABS) substrate is applied as the build plate add-on and a polylactic acid (PLA) filament is used as the deposited material for the experiments and finite element analyses of the material extrusion process
The material extrusion process applied in this paper is based on the fused deposition The material extrusion process applied in this paper is based on the fused deposition modeling (FDM) system of MakerBot Replicator (5th generation) [33]
Summary
The material extrusion (ME) process is a widely used additive manufacturing technique to create three-dimensional prototypes, and final products direct from a computer model. Transient heat transfer models were proposed to estimate the temperature of the ME process and the formation of bonds for a single filament deposition process [30,31]. Heat transfer finite element analysis can be developed to improve the design of process parameters on the deposition characteristics of an additive manufacturing process [32]. An ABS substrate is applied as the build plate add-on and a PLA filament is used as the deposited material for the experiments and finite element analyses of the material extrusion process. Heat transfer finite element analyses (FEAs) using the calibrated FE model are performed to evaluate the proper plate heating temperature of the ABS for deposition of PLA. Materials 2021, 14, 3404 performed to evaluate the proper plate heating temperature of the ABS for deposition of PLA
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