Title: 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.