Investigation on corner precision at different corner angles in material extrusion additive manufacturing: An experimental and computational fluid dynamics analysis

Mollah, Md Tusher; Moetazedian, Amirpasha; Gleadall, Andy; Yan, Jiongyi; Alphonso, Wayne Edgar; Comminal, Raphaël; Šeta, Berin; Lock, Tony; Spangenberg, Jon

Abstract

This paper investigates the influence of different corner angles on microscale geometry in material extrusion additive manufacturing. Polylactic acid (PLA) was 3D-printed with corner angles of 15°, 30°, 45°, 60°, 75°, 90°, and 135° using Bowden and Direct-drive extruders. A computational fluid dynamics (CFD) model was developed to simulate the polymer flow through the extrusion nozzle of both extruders. The simulated corner geometries were compared with experiments to assess simulation accuracy. This included the primary and secondary mitre cross-sectional width through the corner point of the 3D-printed strands. This enabled a new understanding about the prediction accuracy of the CFD model as well as the state of material at the corners, and the deviation of experimental and simulated corners from the analytical one. Moreover, the amount of over-and under-extrusion around the corner was estimated for experimental and simulated studies compared with the analytical corner, which provided fundamental knowledge on corner precision for angular print paths.

Citation

Mollah, M. T., Moetazedian, A., Gleadall, A., Yan, J., Alphonso, W. E., Comminal, R., Šeta, B., Lock, T., & Spangenberg, J. (2022, July). Investigation on corner precision at different corner angles in material extrusion additive manufacturing: An experimental and computational fluid dynamics analysis. Presented at 2022 International Solid Freeform Fabrication Symposium, University of Texas at Austin

• Presentation Conference Type: Conference Paper (published)
• Conference Name: 2022 International Solid Freeform Fabrication Symposium
• Start Date: Jul 25, 2022
• End Date: Jul 27, 2022
• Acceptance Date: Sep 30, 2022
• Online Publication Date: Oct 2, 2022
• Publication Date: Oct 2, 2022
• Deposit Date: Oct 10, 2024
• Publicly Available Date: Oct 18, 2024
• Peer Reviewed: Peer Reviewed
• Pages: 872-881
• Book Title: Proceedings of the 33rd Annual International Solid Freeform Fabrication Symposium
• DOI: https://doi.org/10.26153/tsw/44202
• Keywords: Microscale Corner Precision; Bowden and Direct-drive Extruders; Experiments; Computational Fluid Dynamics; Material Extrusion Additive Manufacturing
• Public URL: https://hull-repository.worktribe.com/output/4864035
• Publisher URL: https://hdl.handle.net/2152/117321