Optimization of overhang printing in ceramic binder jetting additive manufacturing

IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
Wenchao Du, Tianchen Hu, Quinn MacKenzie , Dileep Singh
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Abstract

Cylindrical-shaped horizontally-hanging overhangs with different heights on a solid cubic body were printed via binder jetting additive manufacturing with sililcon carbide powder feedstock. Cracking on the overhang neck and sagging on the overhang body were observed both pre- and post-curing, especially on printed design with a smaller particle size of 10 μm. It was found that the width of cracking and depth of sagging were dependent on the height relative to the solid body in the powder bed, and elevated position of overhang with large volume of underneath loose powder led to increased extend of cracking and sagging. Overhang diameter and weight were varied, which were found with no apparent effects on its deformation extend. To mitigate cracking and sagging, contactless support was designed and tested, which could significantly improve the overhang stability and avoid any overhang deformations. Support gap and support distance were studied for their effects on support capability. The printing processes with and without contactless support were simulated by a finite element modeling approach to understand the stress distribution and evolution of the overhang structures, which revealed stress concentrations on the upper neck point of the designed overhang.
陶瓷粘结剂喷射增材制造中悬垂打印的优化
以碳化硅粉末为原料,采用粘结剂喷射增材制造技术,在固体立方体上打印出不同高度的圆柱形水平悬垂悬垂件。在预固化和后固化过程中,悬垂颈出现裂纹,悬垂体出现下垂,特别是在粒径较小(10 μm)的印刷设计中。研究发现,裂缝的宽度和下垂的深度与粉床内相对于固体体的高度有关,悬垂位置升高,下方有大量松散粉末,导致裂缝和下垂的范围增大。悬垂直径和重量的变化对其变形扩展无明显影响。为了减少裂缝和下垂,设计并测试了非接触式支座,可以显著提高悬垂稳定性,避免悬垂变形。研究了支撑间距和支撑距离对支撑能力的影响。采用有限元建模方法对有和无接触式支撑的打印过程进行了模拟,了解了悬挑结构的应力分布和演化,揭示了设计悬挑上颈点的应力集中。
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来源期刊
Journal of Manufacturing Processes
Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-
CiteScore
10.20
自引率
11.30%
发文量
833
审稿时长
50 days
期刊介绍: The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.
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