Multiphysics modelling of powder bed fusion for polymers

Polymeric materials for powder bed fusion additive manufacturing have been attracting extensive research interest due to their vast potential for fabricating end-use functional parts. Here, a high-fidelity multiphysics approach combining the discrete element model with the computational fluid dynami...

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Main Authors: Tan, Pengfei, Zhou, Meixin, Tang, Chao, Su, Yu, Qi, H. Jerry, Zhou, Kun
Other Authors: School of Mechanical and Aerospace Engineering
Format: Article
Language:English
Published: 2023
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Online Access:https://hdl.handle.net/10356/171080
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Institution: Nanyang Technological University
Language: English
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spelling sg-ntu-dr.10356-1710802023-10-14T16:48:30Z Multiphysics modelling of powder bed fusion for polymers Tan, Pengfei Zhou, Meixin Tang, Chao Su, Yu Qi, H. Jerry Zhou, Kun School of Mechanical and Aerospace Engineering HP-NTU Digital Manufacturing Corporate Lab Singapore Centre for 3D Printing Engineering::Mechanical engineering Additive Manufacturing Selective Laser Sintering Polymeric materials for powder bed fusion additive manufacturing have been attracting extensive research interest due to their vast potential for fabricating end-use functional parts. Here, a high-fidelity multiphysics approach combining the discrete element model with the computational fluid dynamics model has been developed to simulate the printing process of polymers in powder bed fusion, involving powder recoating, melting, and coalescence. The developed approach considers particle flow dynamics, the reflection, absorption, and transmission of infrared laser radiation, and the viscous flow of polymer melt. The pore formation mechanisms due to lack of fusion and gas entrapment in polyamide 12 parts printed via selective laser sintering are studied. The simulation results reveal that lower polymer viscosity would be beneficial to the densification rate of the printed parts. Excessively small powder particles would degrade powder bed quality due to the agglomeration of polymer powder, thus leading to high porosity in the printed parts. Agency for Science, Technology and Research (A*STAR) Published version This study was supported by the RIE2020 Industry Alignment Fund–Industry Collaboration Projects (IAF–ICP) Funding Initiative, Singapore and cash and in-kind contribution from the industry partner, HP Inc. 2023-10-11T07:59:56Z 2023-10-11T07:59:56Z 2023 Journal Article Tan, P., Zhou, M., Tang, C., Su, Y., Qi, H. J. & Zhou, K. (2023). Multiphysics modelling of powder bed fusion for polymers. Virtual and Physical Prototyping, 18(1), e2257191-. https://dx.doi.org/10.1080/17452759.2023.2257191 1745-2759 https://hdl.handle.net/10356/171080 10.1080/17452759.2023.2257191 2-s2.0-85171628215 1 18 e2257191 en Virtual and Physical Prototyping © 2023 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group. This is an Open Access article distributed under the terms of the Creative Commons Attribution-NonCommercial License (http://creativecommons.org/licenses/by-nc/4.0/), which permits unrestricted non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited. The terms on which this article has been published allow the posting of the Accepted Manuscript in a repository by the author(s) or with their consent. application/pdf
institution Nanyang Technological University
building NTU Library
continent Asia
country Singapore
Singapore
content_provider NTU Library
collection DR-NTU
language English
topic Engineering::Mechanical engineering
Additive Manufacturing
Selective Laser Sintering
spellingShingle Engineering::Mechanical engineering
Additive Manufacturing
Selective Laser Sintering
Tan, Pengfei
Zhou, Meixin
Tang, Chao
Su, Yu
Qi, H. Jerry
Zhou, Kun
Multiphysics modelling of powder bed fusion for polymers
description Polymeric materials for powder bed fusion additive manufacturing have been attracting extensive research interest due to their vast potential for fabricating end-use functional parts. Here, a high-fidelity multiphysics approach combining the discrete element model with the computational fluid dynamics model has been developed to simulate the printing process of polymers in powder bed fusion, involving powder recoating, melting, and coalescence. The developed approach considers particle flow dynamics, the reflection, absorption, and transmission of infrared laser radiation, and the viscous flow of polymer melt. The pore formation mechanisms due to lack of fusion and gas entrapment in polyamide 12 parts printed via selective laser sintering are studied. The simulation results reveal that lower polymer viscosity would be beneficial to the densification rate of the printed parts. Excessively small powder particles would degrade powder bed quality due to the agglomeration of polymer powder, thus leading to high porosity in the printed parts.
author2 School of Mechanical and Aerospace Engineering
author_facet School of Mechanical and Aerospace Engineering
Tan, Pengfei
Zhou, Meixin
Tang, Chao
Su, Yu
Qi, H. Jerry
Zhou, Kun
format Article
author Tan, Pengfei
Zhou, Meixin
Tang, Chao
Su, Yu
Qi, H. Jerry
Zhou, Kun
author_sort Tan, Pengfei
title Multiphysics modelling of powder bed fusion for polymers
title_short Multiphysics modelling of powder bed fusion for polymers
title_full Multiphysics modelling of powder bed fusion for polymers
title_fullStr Multiphysics modelling of powder bed fusion for polymers
title_full_unstemmed Multiphysics modelling of powder bed fusion for polymers
title_sort multiphysics modelling of powder bed fusion for polymers
publishDate 2023
url https://hdl.handle.net/10356/171080
_version_ 1781793845967585280