Abstract
This study investigates the thermal-stress characteristics of a large area additive manufacturing to determine a failed additively manufactured build’s temperature profile history and distortion. A thermal-stress simulation model was constructed to recreate the printing process and overall geometry of an experimental build made by material extrusion additive manufacturing. Each layer in the model was created independently, which allows for element birth/death commands and individual layer mesh parameters. The model was developed to use the temperature-dependent heat transfer and mechanical material properties of Acrylonitrile Butadiene Styrene. The temperature profile of the transient thermal-stress model agrees with the experimental thermal profile within a 5% error. The temperature profile results show exponential cooling taking place in the build. Additionally, as the layer print time decreases the heat retention increases the number of layers where the layer temperature is above the glass transition temperature. The stress profile and distortion results from the simulation show that the slumping failure mechanism is caused by a combination of the geometry distortion, heat retention, and material properties.
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