Numerical Study of the Printing Force of Individual Strands in FDM 4D Printing
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In this study, we present a numerical investigation of the deposition of individual strands during Fused Deposition Modeling (FDM) 4D printing. In shape memory polymers (SMP), the shape-shifting property is achieved by applying stresses during printing that are frozen during solidification and later released when the part is heated. In an early work, the measured printing force was used to determine a relationship between printing stress and recovered strain in SMP [1]. Our goal is to explore the numerical forces generated during printing and how these forces depend on key parameters such as cooling rate, nozzle temperature, printing speed, and print gap. Accurately quantifying the effect of these factors is essential for reliably predicting the shape-morphing behavior of the final structure. The high-fidelity numerical model employed in this work solves the thermofluid fields using the stabilized finite element method combined with the arbitrary Eulerian-Lagrangian formulation [2]. A boundary-conforming approach is used to accurately track the free surface motion of the printed strand. The strong shear-thinning and temperature-dependent behavior of the polymer material is characterized by the Cross-WLF viscosity model. Results of the thermofluid fields and printing forces under different process parameters will be presented and discussed. References [1] Ferdinand Cerbe, Dominik Mahlstedt, Michael Sinapius, Christian Hühne, and Markus Böl. Relationship between programming stress and residual strain in FDM 4D printing. Progress in Additive Manufacturing, 2024. [2] Felipe A. González, Stefanie Elgeti, Marek Behr, and Ferdinando Auricchio. A deforming-mesh finite-element approach applied to the large-translation and free-surface scenario of fused deposition modeling. International Journal for Numerical Methods in Fluids, 2023.
