Abstract
Additive manufacturing of plastic parts is a widely spread production method for prototyping. In the recent past, additionally series applications evolved from different sectors of industry. Especially plasticizing processes are characterised by high printing speed and a broad range of materials which can be provided both as filament and granulate. The latter offers the advantage of lower material costs compared to filaments but requires a screw extruder to plasticise and homogenise the plastic melt prior to its deposition through a nozzle. Screw extruders have a wide processing range and therefore are capable of producing a huge variety of printing bead shapes. This shape is directly affected by several extrusion settings and has a great impact on manufacturing time as well as mechanical properties and surface quality of fabricated parts. It would take great effort to determine the influence of process parameters like temperatures and velocities in experimental trials.
In this contribution a process simulation is presented which predicts the bead shape for screw extrusion additive manufacturing. A computation of material flow is performed including nozzle outlet and bead shaping in the gap between nozzle and printing platform. The free surface of the plastic melt is tracked using a volume of fluid method. Numerical investigations follow the concept of Design of Experiments in order to identify significant relationships between extrusion settings and bead shape. By this means, processing windows can be estimated virtually and conclusions can be drawn regarding slicing parameters and manufacturing time.
The results, opinions and conclusions expressed in this thesis are not necessarily those of Volkswagen Aktiengesellschaft.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Dröder, K., Heyn, J.K., Gerbers, R., Wonnenberg, B., Dietrich, F.: Partial additive manufacturing. experiments and prospects with regard to large series production. Proc. CIRP 55, 122–127. Elsevier, Amsterdam (2016)
Hopmann, C., Hellmich, C., Lammert, N., Dormanns, J., Rinderlin, J., Stier, T., Zgrzebski, J.: Schichtweise vom Granulat zum Bauteil. Additive Fertigung von faserverstärkten PA6-Strukturbauteilen in hoher Geschwindigkeit. Kunststoffe 108(11), 22–25 (2018)
Kausch, M., Blasé, J., John, C., Kroll, L., Holzinger, M., Reinhardt, A.: Additive Herstellung von Kunststoffbauteilen im High-Speed-Verfahren unter Einsatz von Standardgranulat. Konstruktion 70(5), 58–60 (2018)
Dröder, K., Reichler, A.-K., Mahlfeld, G., Droß, M., Gerbers, R.: Scalable process chain for flexible production of metal-plastic lightweight structures. Proc. CIRP 85, 195–200. Elsevier, Amsterdam (2019)
Anderson, Jr., J.D.: Governing equations of fluid dynamics. In: Wendt, J. F. (ed.): Computational Fluid Dynamics. An Introduction. Springer, Berlin, Heidelberg (2009).
Du, J., Wei, Z., Wang, X., Wang, J., Chen, Z.: An improved fused deposition modeling process for forming large-size thin-walled parts. J. Mater. Process. Technol. 234, 332–341 (2016)
Xia, H., Lu, J., Dabiri, S., Tryggvason, G.: Fully resolved numerical simulations of fused deposition modeling. Part I – fluid flow. Rapid Prototyping J. 24(2), 463–476 (2018)
Xia, H., Lu, J., Tryggvason, G.: Fully resolved numerical simulations of fused deposition modeling. Part II – solidification, residual stresses and modeling of the nozzle. Rapid Prototyping J. 24(6), 973–987 (2018)
Verma, A., Vishnoi, V., Sukhotskiy, V., Furlani, E.P.: Numerical simulation of extrusion additive manufacturing: fused deposition modeling. TechConnect Briefs 4, 118–121 (2018)
Comminal, R., Serdeczny, M.P., Pedersen, D.B., Spangenberg, J.: Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing. Addit. Manuf. 20, 68–76 (2018)
Serdeczny, M.P., Comminal, R., Pedersen, D.B., Spangenberg, J.: Experimental validation of a numerical model for the strand shape in material extrusion additive manufacturing. Addit. Manuf. 24, 145–153 (2018)
Serdeczny, M.P., Comminal, R., Pedersen, D.B., Spangenberg, J.: Numerical study of the impact of shear thinning behaviour on the strand deposition flow in the extrusion-based additive manufacturing. In: Euspen’s 18th International Conference & Exhibition. Venice, Italy (2018)
Noh, W.F., Woodward, P.: SLIC (Simple Line Interface Calculation). In: Proceedings of Fifth International Conference of Fluid Dynamics, pp. 330–340. Springer, Berlin, Heidelberg (1976)
Osswald, T.A., Rudolph, N.: Polymer Rheology. Fundamentals and Applications. Hanser Publishers, Munich (2015)
Siebertz, K., van Bebber, D., Hochkirchen, T.: Statistische Versuchsplanung. Design of Experiments (DoE). Springer, Heidelberg (2010)
Antony, J.: Design of Experiments for Engineers and Scientists. Elsevier, Amsterdam (2014)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2021 The Author(s), under exclusive license to Springer-Verlag GmbH, DE, part of Springer Nature
About this paper
Cite this paper
Albers, J., Hillemann, U., Retzlaff, A., Hürkamp, A., Dröder, K. (2021). Process Simulation for Screw Extrusion Additive Manufacturing of Plastic Parts. In: Dröder, K., Vietor, T. (eds) Technologies for economic and functional lightweight design. Zukunftstechnologien für den multifunktionalen Leichtbau. Springer Vieweg, Berlin, Heidelberg. https://doi.org/10.1007/978-3-662-62924-6_13
Download citation
DOI: https://doi.org/10.1007/978-3-662-62924-6_13
Published:
Publisher Name: Springer Vieweg, Berlin, Heidelberg
Print ISBN: 978-3-662-62923-9
Online ISBN: 978-3-662-62924-6
eBook Packages: EngineeringEngineering (R0)