Optimization of fused deposition modeling process parameters:a review of current research and future prospects

Fused deposition modeling(FDM) is one of the most popular additive manufacturing technologies for various engineering applications.FDM process has been introduced commercially in early 1990 s by Stratasys Inc.,USA.The quality of FDM processed parts mainly depends on careful selection of process variables.Thus,identification of the FDM process parameters that significantly affect the quality of FDM processed parts is important.In recent years,researchers have explored a number of ways to improve the mechanical properties and part quality using various experimental design techniques and concepts.This article aims to review the research carried out so far in determining and optimizing the process parameters of the FDM process.Several statistical designs of experiments and optimization techniques used for the determination of optimum process parameters have been examined.The trends for future FDM research in this area are described.     

Measurement of heat treatment induced residual stresses by using ESPI combined with hole-drilling method

In this study,residual stresses in heat treated specimen were measured by using ESPI(Electronic Speckle-Pattern Interferometry)combined with the hole-drilling method.The specimen,made of SUS 304austenitic stainless steel,was quenched and water cooled to room temperature.Numerical simulation using a hybrid FDM/FEM package was also carried out to simulate the heat treatment process.As a result,the thermal stress fields were obtained from both the experiment and the numerical simulation.By comparision of stress fields,results from the experimental method and numerical simulation well agreed to each other,therefore,it is proved that the presented experimental method is applicable and reliable for heat treatment induced residual stress measurement.     

Natural convection heat transfer of nanofluids along a vertical plate embedded in porous medium

The unsteady natural convection heat transfer of nanofluid along a vertical plate embedded in porous medium is investigated. The Darcy-Forchheimer model is used to formulate the problem. Thermal conductivity and viscosity models based on a wide range of experimental data of nanofluids and incorporating the velocity-slip effect of the nanoparticle with respect to the base fluid, i.e., Brownian diffusion is used. The effective thermal conductivity of nanofluid in porous media is calculated using copper powder as porous media. The nonlinear governing equations are solved using an unconditionally stable implicit finite difference scheme. In this study, six different types of nanofluids have been compared with respect to the heat transfer enhancement, and the effects of particle concentration, particle size, temperature of the plate, and porosity of the medium on the heat transfer enhancement and skin friction coefficient have been studied in detail. It is found that heat transfer rate increases with the increase in particle concentration up to an optimal level, but on the further increase in particle concentration, the heat transfer rate decreases. For a particular value of particle concentration, small-sized particles enhance the heat transfer rates. On the other hand, skin friction coefficients always increase with the increase in particle concentration and decrease in nanoparticle size.     

连续退火机组辊冷技术及板温控制

介绍了1550mm冷轧单元连续退火机组（CAL）辊冷（RQ）段冷却数学模型,根据数学模型采用有限差分法对RQ出口板温进行实时控制。分析了生产中常见的板温控制问题,就水冷辊位置控制、辊冷段张力、对侧喷吹冷却、后喷吹冷却、机组速度等方面提出相应的板温控制、改善板形的措施。     

CFD在熔融沉积成型挤出头性能分析中的应用

对两种丝料型熔融沉积快速成型(FDM)技术的挤出头进行性能比较分析,所用成型材料为生物可降解塑料聚乳酸(PLA)。应用计算流体动力学软件(CFD)Star CCM+进行挤出头各部件传热以及PLA在挤出头内流道熔融和流动情况的模拟,建立挤出头性能评判指标分别为进料阻力、熔融段长度、能量利用率和准备时间四部分。建立适当的模型和边界条件进行模拟,并监控所需参数,最后通过实验进行进料阻力模拟结果准确性验证,说明用CFD模拟的方法进行3D打印挤出头进料性能对比研究是可行的。     

红外锁相法热波检测技术及缺陷深度测量

研究了红外锁相法热波检测技术的原理、缺陷深度测量及在蜂窝夹层结构及焊接构件检测中的应用。建立了二维热传导有限差分模型,采用该模型计算了强度按正弦规律变化的热流引起试件表面温度变化的历程,基于锁相法提取了有缺陷与无缺陷处的准稳态温度变化,并计算了二者的相位差。然后,建立了热波在试件中传导的热-电等效模型,利用该模型对红外锁相法热波检测技术进行了仿真研究,得到了缺陷深度和反射热波与入射热波相位差之间的关系。最后,采用红外锁相法热波检测技术对模拟缺陷的蜂窝夹层结构试件和实际焊接构件进行了无损检测试验。结果显示,有限差分模型和热-电等效模型计算有缺陷与无缺陷处的相位差与试验结果基本一致,偏差5%,表明采用红外锁相法热波检测技术能够快速、准确地获得缺陷大小、位置等,该技术也适用于有复杂曲面结构的构件。     

脑电遥测和远程监护系统的研制

本文介绍了一种新型的脑电遥测和远程监护系统的研制,利用时分多路复用技术,通过公用电话线传输多导联的脑电信号至监护中心;同时,发射端还同步发送脑电位诱发编码以标识当前传输状态和内容,为监护中心的远程诊断提供依据。对于监护中心而言,则可对波形进行实时显示、冻结、回放、统计分析和存储打印,这一切为远程测量、监护和诊断提供了有力的保障。     

FDM工艺中的尺寸补偿

分析了不同的挤出速度情况下丝的截面模型,计算出相应的理论丝宽值,并进行了丝宽尺寸补偿。在对原型件的尺寸补偿上,综合考虑了各方面的影响因素,得出了正确的补偿量计算公式,并得到了试验结果的证实。     

激光加工微小孔内表面粗糙度的测量

采用激光打孔方法分别加工出直径为 0 2mm、0 2 5mm和 0 3mm的微小孔 ,应用剖分法直接接触式测量得到所加工微小孔的内表面粗糙度 ,并使用反射式显微镜进一步直接观察验证。该测量结果可用于熔融快速原型机喷头的微小孔内表面粗糙度的确定 ,也可用于研究纺丝机、喷墨打印机等类似微小孔时参考     

面向技术问题的3D打印关键技术专利规避设计方法

在工程实践中,为了解决存在的技术问题,需要对现有产品进行创新设计,针对产品创新设计中普遍存在的专利规避需求,结合TRIZ建立了专利规避设计流程,包括规避问题的提出、规避对象的确定和规避设计;以FDM技术为例,对造成FDM技术成型精度低和打印速度慢的问题进行分析,并结合问题原因,专利检索到了在保证打印精度的前提下提高打印速度的技术方案,通过技术迁移,建立了迁移后的初始模型,并利用TRIZ中的功能裁剪进行了专利规避设计和侵权判定,可为企业及研究机构利用专利信息实施专利规避设计提供参考。