Fully Resolved Numerical Simulations of Fused Deposition Modeling. Part II-Solidification, Residual Stresses, and Modeling of the Nozzle

Abstract: Purpose - This paper continues the development of a comprehensive methodology for fully resolved numerical simulations of fusion deposition modeling. Design/methodology/approach - A front-tracking/finite volume method introduced in Part I to simulate the heat transfer and fluid dynamics of the deposition of a polymer filament on a fixed bed is extended by adding an improved model for the injection nozzle, including the shrinkage of the polymer as it cools down, and accounting for stresses in the solid. Findings - The accuracy and convergence properties of the new method are tested by grid refinement and the method is shown to produce convergent solutions for the shape of the filament, the temperature distribution, the shrinkage and the solid stresses. Research limitations/implications - The method presented in the paper focuses on modeling the fluid flow, the cooling and solidification, as well as volume changes and residual stresses, using a relatively simple viscoelastic constitutive model. More complex material models, depending, for example, on the evolution of the configuration tensor, are not included. Practical implications - The ability to carry out fully resolved numerical simulations of the fusion deposition process is expected to be critical for the validation of mathematical models for the material behavior, to help explore new deposition strategies, and to provide the "ground truth" for the development of reduced order models. Originality/value - The paper completes the development of the first numerical method for fully resolved simulation of fusion filament modeling.