Mathematical Model of the Layer-by-Layer FFF/FGF Polymer Extrusion Process for Use in the Algorithm of Numerical...

Area of Science:

• Materials Science
• Additive Manufacturing
• Process Control

Background:

• Fused Filament Fabrication (FFF) is a widely used additive manufacturing technology.
• Maintaining consistent weld quality in FFF is challenging due to thermal variations.
• Existing models often lack real-time control for thermal cycle optimization.

Purpose of the Study:

• To propose and validate a novel approach for improving and maintaining consistent weld quality in FFF.
• To develop a mathematical model integrating real-time nozzle temperature control.
• To enhance the stability and quality of deposited material during the FFF process.

Main Methods:

• Analysis of the FFF printing process thermal cycle.
• Development of a mathematical model with real-time control for numerical implementation.
• Solving the thermal conductivity problem to determine segment-wise heating settings.
• Experimental verification using polylactide 3D printed shapes.
• Simulation of the control system to evaluate regulation quality and stability.

Main Results:

• A mathematical model was developed and validated against experimental and existing models.
• The approach demonstrated the ability to determine segment-wise heating settings for improved weld quality.
• Experimental results showed good correspondence with simulation predictions, with a maximum deviation of 17.7% from thermography data.
• The proposed method ensures high and stable quality of welding in FFF.

Conclusions:

• The developed mathematical model and real-time control strategy effectively improve and maintain consistent weld quality in FFF.
• The approach provides adequate segment-wise heating settings, leading to stable and high-quality 3D printed parts.
• The model's accuracy and the control system's performance were validated through simulations and experiments.