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research-article

Finite element analysis of Additive Manufacturing based on Fused Deposition Modeling (FDM): distortion prediction and comparison with experimental data.

[+] Author and Article Information
Alberto Cattenone

PhD Student, Department of Civil Engineering and Architecture, University of Pavia, Via Ferrata 3, 27100, Pavia, Italy
alberto.cattenone01@universitadipavia.it

Simone Morganti

Assistant Professor, Department of Electrical, Computer, and Biomedical Engineering, University of Pavia, Via Ferrata 5, 27100, Pavia, Italy
simone.morganti@unipv.it

Gianluca Alaimo

Post-Doc Fellow, Department of Civil Engineering and Architecture, University of Pavia, Via Ferrata 3, 27100, Pavia, Italy
gianluca.alaimo01@universitadipavia.it

Ferdinando Auricchio

Full Professor, Department of Civil Engineering and Architecture, University of Pavia, Via Ferrata 3, 27100, Pavia, Italy
auricchi@unipv.it

1Corresponding author.

ASME doi:10.1115/1.4041626 History: Received July 02, 2018; Revised September 25, 2018

Abstract

Additive Manufacturing (or 3D printing) is constantly growing as an innovative process for the production of complex-shape components. Among the seven recognized 3D printing technologies, Fused Deposition Modeling (FDM) covers a very important role, not only for producing representative 3D models, but, mainly due to the development of innovative material like Peek and Ultem, also for realizing structurally functional components. However, being FDM a production process involving high thermal gradients, non-negligible deformations and residual stresses may affect the 3D printed component. In this work we focus on meso/macroscopic simulations of the FDM process using Abaqus software. After describing in detail the methodological process, we investigate the impact of several parameters and modeling choices (e.g. mesh size, material model, time step size) on simulation outcomes and we validate the obtained results with experimental measurements.

Copyright (c) 2018 by ASME
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