Journal Article

Rapid residual stress prediction and feedback control during fused deposition modeling of PLA

Yu, Kang, Li, Hanqiao, Zhu, Qi, Zhang, Qingqing, Tu, Dawei

2022

Overview

Residual stress plays a key role in the mechanical properties and geometry stability of the printing parts during Fused Deposition Modeling (FDM). Being the representative thermoplastic in this type of manufacturing process, the process parameters of polylactic acid (PLA) in FDM have a significant impact on the residual stress of PLA. According to the multiphysics model established, the residual stress decreases with increasing layer thickness, printing speed or platform temperature. Because such traditional finite element analysis takes a long time to calculate the stress, a back propagation (BP) neural network model is established for rapid stress prediction under different processing parameters during FDM. Only 0.56 s is required with such model during each run and the prediction error is controlled in 10%. A close loop system is simulated with temperature modification to mimic an ideal real-time feedback. Meanwhile, by off-line adjusting the FDM process parameters, the residual stress along X direction can be controlled to a certain range from experiments. An intelligent additive manufacturing system can be envisaged with the possibility of stress state modification at any time and any position in the future.

• Publisher: Springer London,Springer Nature B.V
• Subject: Back propagation networks / CAE) and Design / Computer-Aided Engineering (CAD / Engineering / Feedback control / Finite element method / Fused deposition modeling / Industrial and Production Engineering / Manufacturing / Mathematical models / Mechanical Engineering / Mechanical properties / Media Management / Original Article / Polylactic acid / Process parameters / Rapid prototyping / Residual stress / Stress propagation / Thickness