Tu Yiwen, Tan Yuegang, Zhang Fan, Zou Shulin, Zhang Jun
School of Mechanical and Electronic Engineering, Wuhan University of Technology, 205 Luoshi Street, Hongshan District, Wuhan 430062, China.
Polymers (Basel). 2024 Mar 5;16(5):704. doi: 10.3390/polym16050704.
Additive manufacturing (or 3D printing) of continuous carbon fiber-reinforced plastics with fused deposition modeling is a burgeoning manufacturing method because of its potential as a powerful approach to produce lightweight, high strength and complex parts without the need for a mold. Nevertheless, it cannot manufacture parts rapidly due to low throughput. This paper proposes a high-throughput additive manufacturing of continuous carbon fiber-reinforced plastics by multifilament with reference to fiber tape placement. Three filaments were fed and compaction printed simultaneously by a robotic manufacturing system. The coupled thermal-mechanical model of the filament deformation during printing was developed to eliminate the initial interval between the filaments and improved mechanical properties. Furthermore, the mathematical relationship between filament deformation and printing parameters consisting of printing temperature, printing speed and roller pressure was proposed using response surface methodology with the line width as the response. The tensile tests demonstrate that the tensile properties of printed parts are positively correlated with the line width, but not infinitely improved. The maximum tensile strength and tensile modulus are 503.4 MPa and 83.11 Gpa, respectively, which are better than those obtained by traditional methods. Void fraction and scanning electron microscope images also reveal that the appropriate line width achieved by the reasonable printing parameters contributes to the high-throughput multifilament additive manufacturing of continuous carbon fiber-reinforced plastics. The comparison results indicate that the high-throughput multifilament additive manufacturing proposed in this paper can effectively improve the speed of continuous carbon fiber-reinforced plastics additive manufacturing without degrading the mechanical performance.
采用熔融沉积成型法对连续碳纤维增强塑料进行增材制造（或3D打印）是一种新兴的制造方法，因为它有潜力成为一种无需模具就能生产轻质、高强度和复杂零件的强大方法。然而，由于产量低，它无法快速制造零件。本文参照纤维带铺放方式，提出了一种多丝高通量增材制造连续碳纤维增强塑料的方法。通过机器人制造系统同时输送三根丝材并进行压实打印。建立了打印过程中丝材变形的热-机械耦合模型，以消除丝材之间的初始间隙并改善机械性能。此外，以线宽为响应量，采用响应面法提出了丝材变形与由打印温度、打印速度和辊压组成的打印参数之间的数学关系。拉伸试验表明，打印零件的拉伸性能与线宽呈正相关，但并非无限提高。最大拉伸强度和拉伸模量分别为503.4MPa和83.11GPa，优于传统方法获得的性能。孔隙率和扫描电子显微镜图像还表明，合理的打印参数所实现的合适线宽有助于连续碳纤维增强塑料的高通量多丝增材制造。比较结果表明，本文提出的高通量多丝增材制造能够有效提高连续碳纤维增强塑料增材制造的速度，而不降低其机械性能。
