Role of process parameters on the effective properties of the print-bed during binder jet additive manufacturing: A discrete element method-based study

IF 4.5 2区工程技术 Q2 ENGINEERING, CHEMICAL

Powder Technology Pub Date : 2024-07-17 DOI:10.1016/j.powtec.2024.120101

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Abstract

Analysis of the powder spreading process in additive manufacturing (AM) is often based on formation of a single layer of powders on a smooth substrate. While this approach is valid for powder-bed fusion AM techniques, it can oversimplify the printing process in binder jet (BJ-AM), where parts are built through multi-layer spreading of powders with liquid binder added in between. This study analyses the printing process based on multi-layer spreading of powders during BJ-AM process by using Discrete Element Method. The influence of printing parameters including layer thickness, roller velocity and substrate surface roughness on the bulk properties of the print-bed (e.g., density, structural homogeneity, and surface quality) are investigated. The study shows convergence of the relative density of the print-bed toward an asymptotic limit, while structural homogeneity and surface roughness vary significantly with process parameters. A process map is also suggested showing parameter-insensitive window for optimal powder spreading.

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粘合剂喷射增材制造过程中工艺参数对打印床有效特性的影响：基于离散元法的研究

对增材制造（AM）中粉末喷涂过程的分析通常基于在光滑基底上形成单层粉末。虽然这种方法适用于粉末床熔融增材制造技术，但它可能会过度简化粘合剂喷射（BJ-AM）的打印过程，因为这种技术是通过多层粉末铺展并在中间添加液体粘合剂来制造零件的。本研究采用离散元素法分析了 BJ-AM 工艺中基于粉末多层铺展的打印过程。研究了包括层厚、辊筒速度和基底表面粗糙度在内的印刷参数对印床体积特性（如密度、结构均匀性和表面质量）的影响。研究表明，印刷床的相对密度趋于渐近极限，而结构均匀性和表面粗糙度则随工艺参数的变化而显著不同。此外，还提出了一个工艺图，显示了最佳粉末铺展的参数敏感窗口。

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来源期刊

Powder Technology 工程技术-工程：化工

CiteScore

9.90

自引率

15.40%

发文量

1047

审稿时长

46 days

期刊介绍： Powder Technology is an International Journal on the Science and Technology of Wet and Dry Particulate Systems. Powder Technology publishes papers on all aspects of the formation of particles and their characterisation and on the study of systems containing particulate solids. No limitation is imposed on the size of the particles, which may range from nanometre scale, as in pigments or aerosols, to that of mined or quarried materials. The following list of topics is not intended to be comprehensive, but rather to indicate typical subjects which fall within the scope of the journal's interests: Formation and synthesis of particles by precipitation and other methods. Modification of particles by agglomeration, coating, comminution and attrition. Characterisation of the size, shape, surface area, pore structure and strength of particles and agglomerates (including the origins and effects of inter particle forces). Packing, failure, flow and permeability of assemblies of particles. Particle-particle interactions and suspension rheology. Handling and processing operations such as slurry flow, fluidization, pneumatic conveying. Interactions between particles and their environment, including delivery of particulate products to the body. Applications of particle technology in production of pharmaceuticals, chemicals, foods, pigments, structural, and functional materials and in environmental and energy related matters. For materials-oriented contributions we are looking for articles revealing the effect of particle/powder characteristics (size, morphology and composition, in that order) on material performance or functionality and, ideally, comparison to any industrial standard.

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