Investigation of the effectiveness of extruder thermal barrier for additive manufacturing devices by fdm technology

M. Rud; О. Pokhyl; A. Lega; S. Babenko

Journal: Volume 21, No. 4, 2016

Pages: 108 – 113

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Investigation of the effectiveness of extruder thermal barrier for additive manufacturing devices by fdm technology

Abstract

Introduction. Fused deposition modeling (FDM) is the most used techniques of 3D printing. An extruder is the most important element of FDM 3D printer. The extruder is designed for the transportation and distribution of working material in processing zone. In the paper heating unit of 3D printer extruder is studied. A peculiarity of extruder heating unit consists in filament separation on cold and hot zones while minimizing the size of transition zone and maximizing the insulation of hot parts from other parts of the structure. The purpose of scientific work is to identify the effectiveness of extruder thermal barrier for additive manufacturing devices by FDM technology. Formulation of the problem. The transition zone between solid and liquid plastic states plays an important role in the extruder. Too large transition zone increases frictional forces between the filament and cylinder walls. On the other hand, the reduction of transition zone complicates the heating to plastic melting point and therefore reduces printing speed. The main material. To solve this problem thermal barrier of insulating material has been installed. The main objective of developed model is to calculate thermal barrier structure, in which hot and cold parts of the extruder would be properly insulated, and to determine the time required for heating extruder nozzle to operating temperature. As a material for thermal insulation it is offered to use PTFE. Using finite element analysis, a mathematical model of the efficiency of thermal barrier of extruder heating unit is calculated. Conclusions. It is shown that designed thermal barrier of extruder provides reliable thermal insulation and minimal transition zone. The efficiency of thermal barrier is confirmed experimentally. The duration of nozzle heating for the most common heater with the power of 40 W for ABS plastic is about 100 seconds. At the mid-point of thermal barrier 2 mm thick the glass transition temperature for ABS plastic is stabilized approximately during 400 seconds. Outside of thermal barrier the glass transition temperature is not achieved

Keywords

3D-printer, fused deposition modeling (FDM), extruder, finite element method

References

Alhijjaj, M., Belton, P., & Qi, S. (2016). An investigation into the use of polymer blends to improve the printability of and regulate drug release from pharmaceutical solid dispersions prepared via fused deposition modeling (FDM) 3D printing. European Journal of Pharmaceutics and Biopharmaceutics. Available at: http://dx.doi.org/10.1016/j.ejpb.2016.08.016
Chohan, J.S., Singh, R., & Boparai, K.S. (2016). Parametric optimization of fused deposition modeling and vapour smoothing processes for surface finishing of biomedical implant replicas. Measurement. Available at: http://dx.doi.org/10.1016/j.measurement.2016.09.001
Du, J., Wei, Z., Wang, X., Wang, J., & Chen, Z. (2016). An improved fused deposition modeling process for forming large-size thin-walled parts. Journal of Materials Processing Technology. Available at: http://dx.doi.org/10.1016/j.jmatprotec.2016.04.005
Guo, N., & Leu, M.C. (2013). Additive manufacturing: technology, applications and research needs. Frontiers of Mechanical Engineering, 8, 215. Available at: http://doi.org/10.1007/s11465-013-0248-8
Kun, K. (2016). Reconstruction and development of a 3D printer using FDM technology. Procedia Engineering, International Conference on Manufacturing Engineering and Materials (ICMEM), June 6-10, Nový Smokovec, Slovakia, Vol. 149, pp. 203–211.
Mohameda, O.A., Masooda, S.H., & Bhowmikb, J.L. (2016). Mathematical modeling and FDM process parameters optimization using response surface methodology based on Q-optimal design. Applied Mathematical Modelling. Available online 9 July 2016.
Singh, J., Singh, R., & Singh, H. (2016). Repeatability of linear and radial dimension of ABS replicas fabricated by fused deposition modelling and chemical vapor smoothing process: A case study. Measurement. Available at: http://dx.doi.org/10.1016/j.measurement.2016.07.064
Turner, B.N., Strong, R., & Gold, S.A. (n.d.). A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid Prototyping Journal. Available at: http://dx.doi.org/10.1108/RPJ-01-2013-0012
Wang, J., Xie, H., Weng, Z., Senthil, T., & Wu, L. (2016). A novel approach to improve mechanical properties of parts fabricated by fused deposition modeling. Materials & Design. Available at: http://dx.doi.org/10.1016/j.matdes.2016.05.078
Wong, K.V., & Hernandez, A. (2015). A review of additive manufacturing. 3D printing, rapid prototyping, and direct digital manufacturing. Springer, New York, 498 p.

Suggested citation

Rud, M., Pokhyl, O., Lega, A., & Babenko, S. (2016). Investigation of the effectiveness of extruder thermal barrier for additive manufacturing devices by fdm technology. Bulletin of Cherkasy State Technological University, 21(4), 108-113.

[1] Alhijjaj, M., Belton, P., & Qi, S. (2016). An investigation into the use of polymer blends to improve the printability of and regulate drug release from pharmaceutical solid dispersions prepared via fused deposition modeling (FDM) 3D printing. European Journal of Pharmaceutics and Biopharmaceutics. Available at: http://dx.doi.org/10.1016/j.ejpb.2016.08.016

[2] Chohan, J.S., Singh, R., & Boparai, K.S. (2016). Parametric optimization of fused deposition modeling and vapour smoothing processes for surface finishing of biomedical implant replicas. Measurement. Available at: http://dx.doi.org/10.1016/j.measurement.2016.09.001

[3] Du, J., Wei, Z., Wang, X., Wang, J., & Chen, Z. (2016). An improved fused deposition modeling process for forming large-size thin-walled parts. Journal of Materials Processing Technology. Available at: http://dx.doi.org/10.1016/j.jmatprotec.2016.04.005

[4] Guo, N., & Leu, M.C. (2013). Additive manufacturing: technology, applications and research needs. Frontiers of Mechanical Engineering, 8, 215. Available at: http://doi.org/10.1007/s11465-013-0248-8

[5] Kun, K. (2016). Reconstruction and development of a 3D printer using FDM technology. Procedia Engineering, International Conference on Manufacturing Engineering and Materials (ICMEM), June 6-10, Nový Smokovec, Slovakia, Vol. 149, pp. 203–211.

[6] Mohameda, O.A., Masooda, S.H., & Bhowmikb, J.L. (2016). Mathematical modeling and FDM process parameters optimization using response surface methodology based on Q-optimal design. Applied Mathematical Modelling. Available online 9 July 2016.

[7] Singh, J., Singh, R., & Singh, H. (2016). Repeatability of linear and radial dimension of ABS replicas fabricated by fused deposition modelling and chemical vapor smoothing process: A case study. Measurement. Available at: http://dx.doi.org/10.1016/j.measurement.2016.07.064

[8] Turner, B.N., Strong, R., & Gold, S.A. (n.d.). A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid Prototyping Journal. Available at: http://dx.doi.org/10.1108/RPJ-01-2013-0012

[9] Wang, J., Xie, H., Weng, Z., Senthil, T., & Wu, L. (2016). A novel approach to improve mechanical properties of parts fabricated by fused deposition modeling. Materials & Design. Available at: http://dx.doi.org/10.1016/j.matdes.2016.05.078

[10] Wong, K.V., & Hernandez, A. (2015). A review of additive manufacturing. 3D printing, rapid prototyping, and direct digital manufacturing. Springer, New York, 498 p.