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Research Papers: Heat Transfer in Manufacturing

Effect of the Nozzle Radiation on the Fused Filament Fabrication Process: Three-Dimensional Numerical Simulations and Experimental Investigation

[+] Author and Article Information
Benoît Cosson

IMT Lille Douai,
Institut Mines-Télécom,
Polymers and Composites Technology &
Mechanical Engineering Department,
941 rue Charles Bourseul,
Douai 59508, France
e-mail: benoit.cosson@imt-lille-douai.fr

André Chateau Akué Asséko

IMT Lille Douai,
Institut Mines-Télécom,
Polymers and Composites Technology &
Mechanical Engineering Department,
941 rue Charles Bourseul,
Douai 59508, France

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF HEAT TRANSFER. Manuscript received January 17, 2019; final manuscript received April 24, 2019; published online June 12, 2019. Assoc. Editor: Srinath V. Ekkad.

J. Heat Transfer 141(8), 082102 (Jun 12, 2019) (8 pages) Paper No: HT-19-1034; doi: 10.1115/1.4043674 History: Received January 17, 2019; Revised April 24, 2019

This paper addresses heat distribution issues in fused filament fabrication (FFF) process. Three-dimensional (3D) numerical simulations and experimental investigations are performed during additive manufacturing of parts by FFF process. The transient numerical simulations of the filament temperature field are based on the finite difference method. Experimental measurements of the temperature field are carried out using infrared thermography. The proposed model mainly highlights the contribution of heat exchange from the nozzle to the fabricated part and from filament to filament. Optimum adhesion of filaments deposited by FFF requires control of the thermal history. The nozzle radiation is taken into account as a source term in the heat balance equation. The temperature fields of the printed parts computed by numerical simulations are in very good agreement with the temperature fields measured by infrared thermograph. The 3D numerical model provides information on how the nozzle affects the temperature field of the printed part. This source term must be taken into account for the optimization of the FFF process.

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Figures

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Fig. 1

Schematic of fused deposition process [4]

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Fig. 2

Adhesive connections of printed filaments

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Fig. 3

Microscopic observation of deposited filaments

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Fig. 4

Cooling of the filament and temperature distribution at the filament cross section: (a)filament radius = 0.3 mm, initial temperature of filament = 200 °C, heat transfer coefficient = 10 W/(m².°C) and (b) filament radius = 3 mm, initial temperature of filament = 200 °C, heat transfer coefficient = 10 W/(m².°C)

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Fig. 5

Strategy deposition for numerical simulations and printing

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Fig. 6

Different types of contact area

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Fig. 7

View factor calculation between nozzle and deposited filament element: (a) for parallel planes (nozzle above and parallel to the filament) and (b) for perpendicular planes (nozzle above and perpendicular to the filament)

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Fig. 8

(a) Printing zone during the component manufacturing and (b) Illustration (printing layer Lp, Lp − 1 layer below)

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Fig. 9

Experimental thermogram: (a) slow speed and (b) high speed

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Fig. 10

Experimental and numerical temperature evolution, at the point of interest, versus number of lines for high speed

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Fig. 11

Numerical thermogram: (a) slow speed, (b) high speed, and (c) high speed without nozzle radiation

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Fig. 12

Numerical temperature evolution at element 1 versus number of deposited lines for slow and fast speed and without nozzle radiation

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Fig. 13

Influence of the newly deposited filaments on the previously deposited filament on the temperature evolution without nozzle radiation

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