Phase-field modeling of fiber-based thermal diffusion and phase transitions in the fused deposition modeling process

Abstract

This paper introduces an advanced phase-field equation designed to accurately simulate solid–liquid phase transitions and thermal transport during the fused deposition modeling procedure. The model incorporates bidirectional coupling between phase transitions and thermal diffusion, which allows for precise predictions of temperature distribution and detailed tracking of phase evolution influenced by temperature changes. Additionally, it dynamically accounts for the moving heat source in fused deposition modeling by integrating a temperature field that evolves with nozzle movement. To further enhance heat transfer accuracy, a heat convection term combined with the nozzle velocity field is introduced. The proposed algorithm ensures consistency between the digital simulation environment and real-world physical quantities. This consistency provides a highly realistic representation of the fused deposition modeling process. This approach enables effective simulation of temperature distribution and the resulting changes in the geometry and structure of printed parts. It also supports the prediction and optimization of part quality and output in additive manufacturing.