CN113591350B - Material extrusion forming 3D printing forming quality improvement method - Google Patents
Material extrusion forming 3D printing forming quality improvement method Download PDFInfo
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- 239000000463 material Substances 0.000 title claims abstract description 55
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- 238000010146 3D printing Methods 0.000 title claims abstract description 15
- 230000006872 improvement Effects 0.000 title claims description 4
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Classifications
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/28—Design optimisation, verification or simulation using fluid dynamics, e.g. using Navier-Stokes equations or computational fluid dynamics [CFD]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T17/00—Three dimensional [3D] modelling, e.g. data description of 3D objects
- G06T17/20—Finite element generation, e.g. wire-frame surface description, tesselation
Abstract
The invention discloses a material extrusion forming 3D printing forming quality improving method, which comprises the following steps: establishing a three-dimensional geometric model of a forming space fluid domain, performing grid division, and constructing a phase change material model; setting initial and boundary conditions of a calculation domain to obtain a three-dimensional model control equation of a process of extruding materials from a molten state to a substrate deposition solidification; solving a control equation to obtain a dynamic process of extrusion and deposition shaping in material extrusion shaping; extracting profile shape data of a section of the deposited wire; fitting a contour shape mathematical model, and classifying according to the contour shape; replacing an original contour model built in software with the fitted contour shape mathematical model, selecting a corresponding contour model according to different process parameters to carry out path planning and outputting G codes; and processing by using the obtained G code to obtain the formed piece. The invention solves the defect of insufficient forming quality of the existing forming equipment on the forming mechanism, and can further expand the application range of material extrusion forming.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, and particularly relates to a material extrusion forming 3D printing forming quality improving method.
Background
The extrusion molding of the material is the most widely applied thermoplastic polymer 3D printing technology at present, and has the characteristics of high flexibility, low cost and simple process compared with other technologies. The forming principle is that solid thermoplastic filaments are fed into a heated nozzle to change the material from a solid state to a molten state, and then extruded and deposited on a substrate on which a mold is built.
In the same deposited layer, the typical forming process is to print the outer contour first and then fill the inside. Based on this feature, the shape and size of the deposited profile wire determines the profile size of the formed part and the surface roughness of the side walls of the formed part.
The commercial and open source slicing software for extrusion molding of the existing material is fitted by adopting a single monofilament contour model, namely the section shapes for calculating and planning the molding paths are always the same no matter how technological parameters change.
However, this strategy can meet the requirements of the general display or civil forming piece on dimensional precision and performance; however, in the fields of microelectronics, aerospace and the like which use high-temperature and high-performance materials and have high forming precision requirements, the difference of the profile dimensions of the extruded wires after deposition under different process parameters is large, and the popularization and application of the extruded wires are greatly limited by the profile dimension deviation generated in the fitting process.
Disclosure of Invention
The invention aims to solve the technical problem of providing a material extrusion forming 3D printing forming quality improving method aiming at the defects of the prior art.
In order to achieve the technical purpose, the invention adopts the following technical scheme:
a material extrusion forming 3D printing forming quality improvement method, comprising:
step one, establishing a three-dimensional geometric model of a forming space fluid domain according to technological parameters, and carrying out grid division;
defining relevant parameters of the material, and constructing a phase change material model;
step three, setting initial and boundary conditions of a calculation domain according to corresponding technological parameter combinations, and obtaining a three-dimensional model control equation of a process of extruding materials from a molten state to a substrate deposition solidification;
step four, solving a control equation to obtain a dynamic process of extrusion and deposition forming in material extrusion forming;
step five, extracting corresponding solidified deposited wire section profile shape data under different process parameter combinations;
fitting a contour shape mathematical model according to the extracted contour shape, width and height data, and classifying according to the contour shape;
step seven, modifying the slicing software used by the fuse forming equipment, replacing the original built-in contour model in the software by using the contour shape mathematical model obtained in the step six, selecting the corresponding contour model according to different process parameters to carry out path planning and outputting G codes;
and step eight, processing by using the obtained G code to obtain a formed piece.
In order to optimize the technical scheme, the specific measures adopted further comprise:
in the first step, the technological parameters include the inner diameter of the nozzle, the outline dimension of the nozzle and the distance between the nozzle and the substrate;
when a three-dimensional geometric model of a forming space fluid domain is established, regarding the edge of a nozzle and a substrate as boundary conditions of the fluid domain;
and for the nozzle, only constructing a part with the bottom end of the nozzle being 1-5 mm upwards;
the size requirement of the fluid domain meets the requirements of the space for extrusion, deposition and cooling of the single filament, and the range of the length of the fluid domain is at least 3mm or more along the deposition direction according to different process parameters;
when the grid is divided, the nozzle and the gap between the nozzle and the substrate are locally thinned aiming at the high-temperature material;
for low temperature materials, a grid division strategy of global unified parameter scale is used.
In the second step, the relevant parameters of the material include density, viscosity, specific heat and thermal expansion coefficient;
meanwhile, establishing a corresponding relation between viscosity and temperature change for the high-temperature material;
for low temperature materials, a single viscosity parameter is set.
In the third step, the setting of the initial and boundary conditions of the calculation domain specifically includes:
the flow rate of the melt in the nozzle during the forming process, the movement rate of the nozzle, the temperature of the substrate, the temperature of the air, and the correlation coefficient between the various media with respect to heat transfer;
the flow speed of the melt in the nozzle is obtained through conversion of a mass conservation law and a wire feeding speed defined by slicing software, and the specific relation is as follows:
wherein U is the flow velocity of the melt in the nozzle, D is the nozzle inner diameter, vs is the wire feed speed, D S Is the initial diameter of the wire.
In the fifth step, the data extraction position should ensure that the wire deposited at the position is changed from a molten state to a solidified state, and the specific evaluation criteria are as follows: selecting the temperature data as the position below the glass transition temperature of the material;
and establishing a cross section along the direction perpendicular to the extrusion direction of the wire, wherein the projection of the wire on the cross section is the required profile cross section shape.
And step six, fitting a mathematical model of the contour shape according to the extracted contour shape, width and height data, and classifying according to the contour shape, wherein the step six comprises the following steps:
exporting the profile section shape data obtained in the step five, processing the profile section shape data by using software, and establishing a mathematical model corresponding to the fitted profile, wherein the mathematical model comprises coordinate values corresponding to each point of the profile, the maximum width value and the maximum height value of the profile;
counting the size range of the outline, and classifying the extracted mathematical model according to the final forming precision requirement;
where h is the nozzle-to-substrate spacing and d is the nozzle inner diameter.
The seventh step is to modify the slicing software used by the fuse forming device, replace the original contour model built in the software with the fitted contour shape mathematical model, select the corresponding contour model according to different process parameters to perform path planning and output the G code, and the specific method is as follows:
the method comprises the steps of performing secondary development and modification on slicing software applied by target forming equipment, replacing an original contour model built in the software by using a fitted contour shape mathematical model, adding a judging program, enabling the software to automatically select a corresponding section contour model under the parameter combination according to input technological parameters when performing slicing operation, and performing fitting calculation on a processing track of a formed piece by using the selected model, thereby deriving a G code control program which can be identified by the forming equipment.
The invention has the following beneficial effects:
the invention uses the hydrodynamic simulation model to simulate the profile of the formed wire, and is different from the traditional optimization method for improving the mechanical mechanism precision and monitoring feedback readjustment of the forming process.
Drawings
FIG. 1 is an exemplary diagram of a three-dimensional geometric model of a forming space fluid domain.
Fig. 2 is a diagram of an example of a local mesh refinement site.
FIG. 3 is an exemplary drawing of an extracted deposited wire cross-sectional profile model.
FIG. 4 is an exemplary illustration of the cross-sectional profile shape of a wire taken by the slicing software.
Fig. 5 is a flow chart of an implementation process.
Detailed Description
Embodiments of the present invention are described in further detail below with reference to the accompanying drawings.
Referring to fig. 5, the method for improving the 3D printing forming quality of material extrusion forming according to the present invention improves the 3D printing forming quality of material extrusion forming by using a hydrodynamic simulation model, and includes:
step one, establishing a three-dimensional geometric model of a forming space fluid domain according to technological parameters, and carrying out grid division;
the specific method comprises the following steps:
as shown in fig. 1, a three-dimensional geometric model of the forming space fluid domain capable of reflecting the actual size is created according to the process parameters (nozzle inner diameter, nozzle outer dimension, nozzle-to-substrate spacing, etc.).
In this process, the nozzles, substrates, etc. need not be constructed in solid form, and only their edges need to be the boundary conditions for the fluid domain, i.e., the process is a multiphase flow simulation.
For the nozzle, only a part with the bottom end of the nozzle being 1-5 mm upwards is needed to be constructed;
the construction of the size of the whole fluid domain only needs to meet the requirement of a space for single filament extrusion, deposition and cooling, and the range of the length of the fluid domain is at least 3mm or more along the deposition direction according to different process parameters; the deposited wire is typically taken to have a length dimension of 5mm.
Regarding grid division, regarding high temperature materials (such as PEEK materials), because the influence of viscosity-temperature change on morphology is considered, if the nozzle and the gap between the nozzle and the substrate can be locally thinned for improving the calculation efficiency, as shown in FIG. 2;
and aiming at low-temperature materials (such as common PLA, ABS and the like), the fitting precision can be met by using single viscosity setting, and the grid division strategy with global uniform parameter scale can be used because the calculation amount is small, so that the stability in calculation is improved.
Defining relevant parameters of the material, and constructing a phase change material model;
leading in material related parameters, constructing a phase change material model with a viscosity-temperature corresponding relation, and specifically:
and defining relevant parameters of the material, and generating a model which can accurately reflect the phase change process of the material, namely a phase change material model. The method is mainly defined as parameters (such as density, viscosity, specific heat, thermal expansion coefficient and the like) related to heat of materials, and meanwhile, for high-temperature materials with larger glass transition temperature and melting temperature (such as PEEK and the like), the influence of great difference of viscosity on morphology in a larger temperature gradient in the melting and solidification process needs to be considered, and the corresponding relation between the viscosity and temperature change needs to be established, so that the accuracy of the simulated outline shape can be effectively improved;
and aiming at common low-temperature materials (such as PLA, ABS and the like), only a single viscosity parameter is required to be set, so that a profile fitting result with higher precision can be obtained.
Step three, setting initial and boundary conditions of a calculation domain according to corresponding technological parameter combinations, and obtaining a three-dimensional model control equation of a process of extruding materials from a molten state to a substrate deposition solidification;
step four, solving a control equation to obtain a dynamic process of extrusion and deposition forming in material extrusion forming;
the initial and boundary conditions of the calculation domain are set according to the corresponding process parameter combinations. The method specifically comprises the following steps:
the flow rate of the melt in the nozzle during the forming process, the velocity of the movement of the nozzle, the temperature of the substrate, the temperature of the air (used to simulate the chamber temperature), and the correlation coefficient between the various media with respect to heat transfer, etc.
The flow velocity of the melt in the nozzle referred to herein need not be obtained by complex actual measurements, but can be scaled by mass conservation laws and slicing software-defined wire feed speeds, as specified by the relationship:
wherein U is the flow velocity of the melt in the nozzle, D is the nozzle inner diameter, vs is the wire feed speed, D S Is the initial diameter of the wire.
Through the arrangement, a three-dimensional model control equation of the process of extruding the material from a molten state to the deposition solidification of the substrate is obtained, and finally, the dynamic process of extrusion and deposition forming in material extrusion forming is solved.
Step five, extracting corresponding solidified deposited wire section profile shape data under different process parameter combinations, wherein the specific method comprises the following steps:
in the post-processing of the simulation results, the sampling position should ensure that the wire deposited at the position has changed from a molten state to a solidified state, and the specific evaluation criteria may select the temperature data as the position below the glass transition temperature of the material, because the material is in the solidified state at this temperature. And establishing a cross section along the direction perpendicular to the extrusion direction of the wire, wherein the projection of the wire on the cross section is the required profile cross section shape.
Fitting a contour shape mathematical model according to the extracted contour shape, width and height data, and classifying according to the contour shape;
the specific method comprises the following steps:
and D, deriving the profile section shape data obtained in the step five, processing the profile section shape data by using software, and establishing a mathematical model corresponding to the fitted profile, wherein the mathematical model comprises coordinate values corresponding to each point of the profile, the maximum width value, the maximum height value and the like of the profile.
The size range of the profile is counted, the extracted profile mathematical model is classified according to the final forming precision requirement, as shown in fig. 3, the obtained profile shape is divided into 3 types, corresponding process parameter windows are h/d=0.5, h/d=0.75 and h/d=1 respectively, wherein h is the distance between the nozzle and the substrate, and d is the inner diameter of the nozzle.
The more the profile shape classification is, the higher the precision of the final formed piece is, but the lower the data processing efficiency is when slicing; the less the profile shape classification, the lower the precision of the final form, but the faster the data processing efficiency at the time of slicing. The outline shape classification is reasonably divided according to the precision requirement of the formed piece, and the optimal effect can be obtained.
And step seven, modifying the slicing software used by the fuse forming equipment, replacing the original built-in contour model (figure 4) in the software by using the contour shape mathematical model obtained in the step six, enabling the program to realize path planning by selecting the corresponding contour model according to different process parameters, and outputting G codes. The specific method comprises the following steps:
the method comprises the steps of performing secondary development and modification on slicing software applied by target forming equipment, replacing an original contour model built in the software by using a fitted contour shape mathematical model, adding a judging program, enabling the software to automatically select a corresponding section contour model under the parameter combination according to input technological parameters when performing slicing operation, and performing fitting calculation on a processing track of a formed piece by using the selected model, thereby deriving a G code control program which can be identified by the forming equipment.
And step eight, forming by using the G code to obtain a formed piece.
And (3) transmitting the G code file output in the last step to forming and processing equipment for processing, and finally obtaining the designed formed piece.
The invention solves the defect of insufficient forming quality of the existing forming equipment on the forming mechanism, and can further expand the application range of material extrusion forming.
The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above examples, and all technical solutions belonging to the concept of the present invention belong to the protection scope of the present invention. It should be noted that modifications and adaptations to the invention without departing from the principles thereof are intended to be within the scope of the invention as set forth in the following claims.
Claims (6)
1. A material extrusion 3D printing forming quality improvement method, comprising:
step one, establishing a three-dimensional geometric model of a forming space fluid domain according to technological parameters, and carrying out grid division;
in the first step, the technological parameters comprise the inner diameter of the nozzle, the outline dimension of the nozzle and the interval between the nozzle and the substrate;
when a three-dimensional geometric model of a forming space fluid domain is established, regarding the edge of a nozzle and a substrate as boundary conditions of the fluid domain;
and for the nozzle, only constructing a part with the bottom end of the nozzle being 1-5 mm upwards;
the size requirement of the fluid domain meets the requirements of the space for extrusion, deposition and cooling of the single filament, and the range of the length of the fluid domain is at least 3mm or more along the deposition direction according to different process parameters;
when the grid is divided, the nozzle and the gap between the nozzle and the substrate are locally thinned aiming at the high-temperature material;
for low-temperature materials, a grid division strategy of global unified parameter scale is used;
defining relevant parameters of the material, and constructing a phase change material model;
step three, setting initial and boundary conditions of a calculation domain according to corresponding technological parameter combinations, and obtaining a three-dimensional model control equation of a process of extruding materials from a molten state to a substrate deposition solidification;
step four, solving a control equation to obtain a dynamic process of extrusion and deposition forming in material extrusion forming;
step five, extracting corresponding solidified deposited wire section profile shape data under different process parameter combinations;
fitting a contour shape mathematical model according to the extracted contour shape, width and height data, and classifying according to the contour shape;
step seven, modifying the slicing software used by the fuse forming equipment, replacing the original built-in contour model in the software by using the contour shape mathematical model obtained in the step six, selecting the corresponding contour model according to different process parameters to carry out path planning and outputting G codes;
and step eight, processing by using the obtained G code to obtain a formed piece.
2. The method for improving the quality of 3D printing of a material extrusion molded according to claim 1, wherein in the second step, the related parameters of the material include density, viscosity, specific heat and thermal expansion coefficient;
meanwhile, establishing a corresponding relation between viscosity and temperature change for the high-temperature material;
for low temperature materials, a single viscosity parameter is set.
3. The method for improving the quality of 3D printing of material extrusion molding according to claim 1, wherein in the third step, initial and boundary conditions of a calculation domain are set, specifically comprising:
the flow rate of the melt in the nozzle during the forming process, the movement rate of the nozzle, the temperature of the substrate, the temperature of the air, and the correlation coefficient between the various media with respect to heat transfer;
the flow speed of the melt in the nozzle is obtained through conversion of a mass conservation law and a wire feeding speed defined by slicing software, and the specific relation is as follows:
wherein U is the flow velocity of the melt in the nozzle, D is the nozzle inner diameter, vs is the wire feed speed, D S Is the initial diameter of the wire.
4. The method for improving the quality of 3D printing of a material extrusion process according to claim 1, wherein in the fifth step, the data extraction location should ensure that the wire deposited at the location has changed from a molten state to a solidified state, and the specific criteria are: selecting the temperature data as the position below the glass transition temperature of the material;
and establishing a cross section along the direction perpendicular to the extrusion direction of the wire, wherein the projection of the wire on the cross section is the required profile cross section shape.
5. The method for improving the quality of 3D printing of material extrusion molding according to claim 1, wherein in step six, a mathematical model of the profile shape is fitted according to the extracted profile shape, width and height data, and the classification is performed according to the profile shape, comprising:
exporting the profile section shape data obtained in the step five, processing the profile section shape data by using software, and establishing a mathematical model corresponding to the fitted profile, wherein the mathematical model comprises coordinate values corresponding to each point of the profile, the maximum width value and the maximum height value of the profile;
and counting the size range of the profile, and classifying the extracted mathematical model according to the final forming precision requirement.
6. The method for improving the quality of 3D printing and forming of material extrusion forming according to claim 1, wherein in step seven, the slicing software used by the fuse forming device is modified, the fitted mathematical model of the contour shape is used to replace the original model of the contour built in the software, and the corresponding model of the contour is selected according to different process parameters to perform path planning and output G codes, and the specific method is as follows:
the method comprises the steps of performing secondary development and modification on slicing software applied by target forming equipment, replacing an original contour model built in the software by using a fitted contour shape mathematical model, adding a judging program, enabling the software to automatically select a corresponding section contour model under the parameter combination according to input technological parameters when performing slicing operation, and performing fitting calculation on a processing track of a formed piece by using the selected model, thereby deriving a G code control program which can be identified by the forming equipment.
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| CN114953439B (en) * | 2022-06-21 | 2023-05-30 | 深圳大学 | Prediction method of deposited corner outline in direct-write 3D printing |
| CN116690991A (en) * | 2023-05-20 | 2023-09-05 | 南京航空航天大学 | Method for dynamically regulating and controlling 3D printing extrusion flow in real time |
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