Yang Zhuoran, Wang Feibo, Dun Yiheng, Li Dinghe
Sino-European Institute of Aviation Engineering, Civil Aviation University of China, Tianjin 300300, China.
Aeronautical Engineering Institute, Civil Aviation University of China, Tianjin 300300, China.
Polymers (Basel). 2025 Apr 10;17(8):1026. doi: 10.3390/polym17081026.
Fused deposition modeling (FDM), as one of the most widespread and cost-effective additive manufacturing (AM) technologies, faces ongoing challenges in improving the dimensional accuracy and mechanical properties of complex shapes. The repeated heating and cooling of thermoplastic filaments make the FDM parts prone to accumulating warping deformation, which is difficult to predict due to the specificity of material deposition toolpaths. In this study, a path-based discrete modeling and process simulation method was developed for the FDM process. Based on process parameters and material deposition toolpaths, the finite element (FE) model was reconstructed using the discrete modeling method. Then, the birth-death element method (BDEM) was employed to simulate the FDM process and solve the thermo-mechanical coupling field in ANSYS 2022 R1. The corresponding computing programs were compiled in C++. The effectiveness of the proposed method was verified by three numerical examples using ABS material. According to the results, the simulated deformations show strong agreement with the deformations of real FDM parts. The findings of this study are applicable to other mainstream AM processes and are unrestricted by any complex geometries.
熔融沉积建模（FDM）作为最广泛应用且具成本效益的增材制造（AM）技术之一，在提高复杂形状的尺寸精度和机械性能方面面临持续挑战。热塑性长丝的反复加热和冷却使FDM零件易于累积翘曲变形，由于材料沉积路径的特殊性，这种变形难以预测。在本研究中，针对FDM工艺开发了一种基于路径的离散建模和过程模拟方法。基于工艺参数和材料沉积路径，采用离散建模方法重建有限元（FE）模型。然后，运用生死单元法（BDEM）在ANSYS 2022 R1中模拟FDM工艺并求解热-机械耦合场。相应的计算程序用C++编写。使用ABS材料的三个数值例子验证了所提方法的有效性。根据结果，模拟变形与实际FDM零件的变形高度吻合。本研究结果适用于其他主流增材制造工艺，且不受任何复杂几何形状的限制。
