Radiative Thermal Effects in Large Scale Additive Manufacturing of Polymers: Numerical and Experimental Investigations.

Benoît Cosson,Christian Hopmann,André Chateau Akué Asséko,Lukas Pelzer

doi:10.3390/ma15031052

Benoît Cosson, Christian Hopmann + Show 2 more

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https://doi.org/10.3390/ma15031052

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Abstract

The present paper addresses experimental and numerical investigations of a Large Scale Additive Manufacturing (LSAM) process using polymers. By producing large components without geometrical constraints quickly and economically, LSAM processes have the capability to revolutionize many industries. Accurate prediction and control of the thermal history is key for a successful manufacturing process and for achieving high quality and good mechanical properties of the manufactured part. During the LSAM process, the heat emitted by the nozzle leads to an increase in the temperature of the previously deposited layer, which prepares the surface for better adhesion of the new layer. It is therefore necessary to take into account this part of heat source in the transient heat transfer equation to correctly and completely describe the process and predict the temperature field of the manufactured part. The present study contributes to experimental investigations and numerical analysis during the LSAM process. During the process, two types of measurements are performed: firstly, the heat emitted by the nozzle is measured via a radiative heat sensor; secondly, the temperature field is measured using an infrared camera while varying the process speed. At the same time, a numerical simulation model is developed in order to validate the experimental results. The temperature fields of the manufactured parts computed by numerical simulations are in very good agreement with the temperature fields measured by infrared thermograph with the contribution of the nozzle’s heat exchange.

Highlights

The industrial use of Additive Manufacturing (AM) is growing rapidly in many areas.The technology’s applications range from medical to aerospace
AM allows the manufacturing of parts with complex shapes, difficult to achieve by conventional processes
Especially for parts obtained by extrusion-based AM technologies such as Fused Deposition

Summary

Introduction

The industrial use of Additive Manufacturing (AM) is growing rapidly in many areas.The technology’s applications range from medical to aerospace. AM allows the manufacturing of parts with complex shapes, difficult to achieve by conventional processes. Especially for parts obtained by extrusion-based AM technologies such as Fused Deposition. Modeling (FDM), mechanical properties of the manufactured parts are oftentimes inferior as compared to parts manufactured by conventional processes such as injection molding. To improve the mechanical properties of parts manufactured by FDM, two approaches can be used. The first one is to improve the intrinsic properties of the constitutive material of the filament by adding reinforcements of different kinds in the thermoplastic [1,2,3,4]. The second approach, especially when high mechanical properties are required, is the optimization of process parameters [5,6,7]

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